analysis and redesign of w- type radiant tube using finite element method
TRANSCRIPT
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
1/18
ANALYSIS AND REDESIGN OF W- TYPE RADIANT
TUBE USING FINITE ELEMENT METHOD
INTERNAL GUIDE:
Mr.M.Varatharajulu,B.E., M.B.A
(Asst. Professor),
Dept. Of Mechanical Engg.
PRESENT BY
M.Akbar Ali
A.HajaSheikAlavuden
V .Saravanan
M .Venkateshwaran
EXTERNAL GUIDE:
Mr. A. Karuppiah. M.EManagerCold Mill (SSTP)BHEL. (Trichy)
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
2/18
To analyze and to find out the failurecauses of the radiant tube.
Provide solution for the failure of radiantTube.
Comparing the solution with the existingdesign.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
3/18
INTRODUTION ABOUT RADIANT TUBE
Radiant tubes are heat transfer mountings.
Gases by convection and radiation transfers heat to the
radiant tube.
The heated tube transfers energy to the furnace, by means
of convection and radiative heat transfer.
There are three types of radiant tube P-type ,W-type& U-
type.
Our project is concerned with w-type radiant tube.
Material of the radiant tubes are nickel chrome steel.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
4/18
PROBLEM DESCRIPTON
Radiant tubes are designed to operate at 960C; the furnace
temperature is maintained between 700C and 1100C by a
design requirement based on the tube thickness.
Due to the uneven heating, the radiant tubes werefrequently damaged after their rated service.
In general, the damage style of a number of the tubes is
almost the same. The failure mode of the tubes appeared tobe in the surface of the tube, about 6590 cm from the
burner-mounting flange.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
5/18
METHODOLOGY
The analysis can be carried out using ANSYS software
In general, there are three steps in the development of
a finite element model.
Developing a geometrical model, selecting an
element, determining material properties and finally
converting the geometrical model to a finite element
model by griding.
Applying boundary and initial conditions, loading
and performing calculations based on the model.
Extracting results.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
6/18
Contd.
Modeling of the radiant tube was done by using Pro-e software.
The model is imported to the ANSYS and imported model is
meshed.
And finally using ANSYS software, the analysis of the radianttube was done.
The results were obtained for various parameters liketemperature distribution, equivalent stress and total
deformation. The results obtained for suggested model were compared
with the existing model.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
7/18
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
8/18
Contd.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
9/18
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
10/18
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
11/18
RESULTS & DISCUSSION
S.NoApproximate Distance from
burner-mounting flange (mm)
1 0 - 300
2 300 - 600
3 600 - 1000
4 1000 - 1500
5 1500 - 2500
6 2500 - 4500
7 4500 - 5000
8 5000 - 5500
9 5500 - 6000
10 6000 - 6600
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
12/18
Suggestion IIt is suggested to increase the thickness of the wall in the Radiant tube.
Suggestion II
It is suggested to change the material properties, which will withstand the load
against the exiting failure.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
13/18
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
14/18
Observation From the above charts it is observed that the
temperature distribution, equivalent stress and thetotal deformation are high at the critical region in allthe cases.
The suggestion II model exhibits very low stress anddeformation compared to other two models.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
15/18
Material ComparisonExisting material properties Innovated material properties Reason and cause
Elements / Name of
the materialDIN17456 (STD) SA 106 Grade A.
C 0.35 to 0.55% 0.35To reduce the
hardenability
Si 1.0 to 2.0% 1.2
To increase the toughness
and strength at high
temperature
Mn 1.5% 1.5
To increase the resistance
to cracking at high
temperature
P 0.040 % 0.040To keep the same
weldability
S 0.030 % 0.030To keep the impact
toughness
Cr 27.0 to 30.0 % 30.00
To increase the corrosion
resistance at high
temperature
Ni 47.0 to 50.0 % 50.00 To increase the strength
Mo 0.05% 0.05
To increase the high
temperature tensile
strength
W 4.0 to 6.0 % 6To withstand the high
temperature
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
16/18
Conclusion. Radiant tubes are designed to operate at 960C; but
the furnace temperature is required maintained
between 700C and 1100C, so it is required to
change the material of the radiant tube.
Analysis of the radiant tube carried out using ANSYSWORKBENCH Software
Results had been obtained for Temperature
distribution, Equivalent Stress and for Totaldeformation for different models.
Graphs have been plotted between Temperaturedistribution and distance, Equivalent stress and
distance and between total deformation and distance
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
17/18
Contd.
Compared to the existing model, the suggested model I isfound to have 21.05% lesser stress and 21.05% lesser total
deformation.
Compared to existing model suggested model II have
34.21% lesser stress and 31.24% lesser deformation. By this analysis it is found that the suggested models have
higher strength and higher temperature withstanding
capability than the existing model.
It is suggested that to use model II for the effective usewithout fail for the longer period than the other two
models.
-
7/31/2019 Analysis and Redesign of W- Type Radiant Tube Using Finite Element Method
18/18
THANK YOU