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DEPARTMENT OF MECHANICAL ENGINEERING
TEZPUR UNIVERSITY
By,
Angshuman Sharma (MEB11013)
Deepjyoti Das (MEB11023)
Pranjal Das (MEB1106)
Under the Supervision of Dr. SANJIB BANERJEE (Assistant Professor
Design And Fabrication of a Furnace to
InvestigateHigh temperature Deformation
Behaviour
B. Tech fnal year project 2014-2015
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!ntro"u#tion
$iterature re%ie&
'igh temperature "eormation eha%ior
*urna#es &ith loa"ing pro%isions
+je#ti%es
Propose" Design
Dimensions o the urna#eDesigning the heating element
,al#ulations
Materials an" instruments use"
Metho"s o ari#ation a"opte"
-esultsDis#ussions
,on#lusion
S#ope o uture &or./ o%elty
-eeren#es
Table of Contents
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'igh temperature "eormation eha%ior analysis o "ierent materialsis an area &hi#h has en#ountere" a re#ent in#rease in interest
Material properties are the %ery asi#s &hi#h &oul" result into them
eing use" or the ari#ation "ierent oje#ts an" stru#ture Also/ there
are many oje#ts an" stru#tures &hi#h are re4uire" to sur%i%e an"
perorm un"er harsh #on"itions li.e high temperature/ pressure et# !t e#omes imperati%e that &e ha%e a #onsi"erale .no&le"ge o
some materials un"er su#h #on"itions
'o&e%er the a%ailale set ups to perorm su#h tests put up a "istin#t
loophole 5here is a general s#ar#ity o #ommer#ially pro"u#e" rea"y
ma"e apparatus that has pro%isions o oth high temperature
generation an" loa" appli#ation #onine" into one single unit
5hus &e #ame or&ar" &ith the i"ea o "esigning an" ari#ating a lo&
#ost urna#e that &oul" not only heat the spe#imen ut &ill also ha%e
pro%isions to pro%i"e loa" on the spe#imen
Introduction
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!lori/ (11/igeria) e7amine" the "etaile" aspe#ts an" #onstraints
a#e" &hile "esigning an resistan#e urna#e Benoit Boulet/ 8ino $alli/ Mar. Ajers#h (2003) perorme" an analysis
on the #ontrol o an ele#tri# urna#e
,hu/ S8 An" $i/ 9,M/ !mpression #reep: a ne& test/ 9ournal o
material s#ien#e/ (1;;)/ has a "etaile" "es#ription o the test
parameters
High temperature deformation test:As the name suggests/ it is the
plasti# "eormation o##urring in materials &hen suje#te" to high
temperature situation un"er the a#tion o some loa" 5here o##urs
irre%ersile #hange o shape o a #rystal or an aggregate o #rystalsin the soli" stru#ture o the material spe#imen in response to e7ternal
or#es
Some o the #ommon high temperature "eormation tests &oul" e
#reep testing at #onstant stress/ "eormation analysis at #onstant
strainrate / high temperature #ompression test
Literature Review
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5o ha%e pro%ision or loa"ing in or"er to a#ilitate "eormation testing o
spe#imen
5o attain %ery high temperature in or"er to a#ilitate testing o a range o
"ierent materials
5o ha%e pro%isions or atta#hment o %arious sensors or "ete#ting an"
re#or"ing "ata re4uire" or analysis o me#hani#al properties o the test
spe#imen
5o ma.e the "esign a #ompa#t one so that it #an e atta#he" to any set up
that &oul" re4uire this urna#e
5o .eep the &eight o the urna#e an" #ost o pro"u#tion at the minimum
possile e7tent
5o a#hie%e soun" insulation an" meet the saety re4uirements y using
proper rera#tory materials
Objectives
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Type of furnace we are fabricating: -esistan#e heating urna#e rinciple: !t tra#es its &or.ing prin#iple to the %ery asi# ormula:
Dierent possile arrangements or loa" a""ition:
Literature Review !!contd
2H I RT=
Fi! "#$ Hori%onta&&' o)in! in*enter set +, Fi! "-$ Stationar'in*enter set +,
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Literature Review
Fi! ".$ Verti/a& o)eent ofin*enter
5his set up is preerre" as it is simple an" no &or. has to e "one against
gra%ity
5he "esign is a##epte" as more a##ura#y #an e a#hie%e" y it an" there
is lesser proaility o "ele#tions #ause" y any .in" o or#es
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The roposed "esign!
Fi!$ "01 Desi!n of t2e entire
set +,
Fi!$ "31 S/2eati/ of t2e set
+,
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"imensions of Components!
Individua components !from topto bottom"
# &oa* ,&ate 4it2 a /'&in*ri/a& 5an!e10 s+,,ortin! ro*s1# /'&in*ri/a& 6+s2 (6earin!1
# s+,,ort ,&ate1# a&+ina ro*# /o)er ,&ate 4it2 a /ir/+&ar 2o&e n s&ot1# /'&in*ri/a& /asin!1# a&+ina t+6e1
# s&ee)e1# in*enter1# 2eatin! e&eent in s,rin! for1# /erai/ ,&ate for sa,&e ,&a/in!# 6ase ,&ate1
Fi!$ "71 Front an* to, )ie4 of t2e
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MATERIALS USED
#! $ild steel: %&or Lid' (ase plate and Cover or Casing)
Properties o mil" steel are :
-easonaly high stru#tural strength 'ar" an" malleale Mil" steel #an e ma#hine" an" shape" easily
"ue to its inherent le7iility
*! Ceramic %+l*O,): %&or ceramic plate' Aumina
tube# Aumina rod)
Material properties o the #erami# are :
Ma7imum #ontinuous ser%i#e temperature up to
3000
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MATERIALS USED
,! Heating element: %-ichrome wire)
Properties o ni#hrome &ire are :
Melting point is upto
'igh thermal #on"u#ti%ity(113 >?m@)
'igher resisti%ity At room temperature
resisti%ity(11 )
C1400
m10 6
*ig:0 i#hrome &ire
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MATERIALS USED
.! High/temperature insulation wool %Ceramic wool):
Properties o the #erami# &ool are :
5hey are light&eight an" ha%e lo& thermal
#on"u#ti%ities
E7#ellent resistan#e to thermal sho#.+utstan"ing ele#tri#al resisti%ity
*ig:10 ,erami# &ool
0! +dhesive %1odium silicate 2 +lumina):
Properties are :
8oo" a"hesi%e #hara#teristi#s'igh "iele#tri# strength or ele#tri#al insulation
*ig:11 #erami# #ementpaste
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Instr+ents
*! 3ariac:
-ange: 02;0C
$, : 2C
,! Controller:
,omponents o #ontroller:
(i) 5emperature "isplay(ii) Ammeter
(iii) -elay
(i%) ,utout
*ig 13: Caria#
*ig1 : ,ontroller
#! "ial 4auge (&ith gauge stan"):
$east ,ount : 001mm
*ig:12 Dial 8auge &ith gauge
stan"
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5o "esign the heating element &e nee" to in" out the %alues o "ierent
"imensions "es#riing the &ire 5hey are
15he length o the heating element
2 5he total numer o turns o the spring o the heating element
*or in"ing all these %alues/ &e employ "ierent empiri#al relations/ &hi#h
pre#lu"es the #onsi"eration o "ierent parameters5hey are
(a) Mass o the air insi"e the alumina tue
() Mass o the alumina tue
(#) 'eat generate" in air trappe" insi"e the tue
(") 'eat generate" in the tue
(e) 'eat re4uire" in the sample
() 5otal heat pro"u#e"
(g) -esistan#e o the heating element
Design o the heating element
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Calculations involved are shown se5uentially
#!Calculating the mass of air
&ormula involved 8
8 9!
&here, : "ensity o air at t ,:
Mass o air v : %olume o air insi"e the tue
l : length o the alumina tue (mm) 01 .g d : inner"iameter o the tue (mm
or d 3= mm/l 10 mm, 122 .g?m3("ensity o air at 2; +,)
*! Calculating the mass of tube
&ormula involved &here/ : "ensity o alumina
% : %olume o tue
Mass o tue
02 .g
or R2 26mm, R1 1mm, l10mm/ 3 gm?#m3
Design o the heating element
v
2 ld
D
1D00E03=0E1D3E22B1 2
val lRR
al)( 2
1
2
2 -
100)10260(1330 22 0.0-
al
al
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$.Calculating the heat generated in air
&ormula involved 6 &here/ ma: mass o air
'eat generate" : #hange in temperature
136; .9 ,a : spe#ii# heat o air
*or ,a 100 .9?.g@ / F5 ;00 ,/ m: a 01 .g
.! Calculating the heat generated in tube &ormula involved 6 &here' mal: mass o tue
'eat generate" in tue #al : spe#ii# heat o tue
366; .9 F 5 : #hange in temperature
*or ,al==0 9?.g@/ F5 ;00 ,/ m: al 02 .g
0! Calculating the heat re5uired for the sample
&ormula involved 6
'eat re4uire" or the sample or m 000 .g
30 2 .9 # =6 .9?.g@
Design o the heating element
Tcm aa F
;0000110 TF
Tcmalal
FEE
;00==020
Tcm F
;00E=6DE0B030
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Design o the heating element
7! Calculating the total heat generated
Total heat generated 'eat generate" in sampleG 'eat generate" in air
G'eat generate" in tue
= 136; G 366; G 302 .9
313= .9
8! Calculating the resistance of the heating element 5otal heat generate"/ &here : ei#ien#y
I : #urrent
R : resistan#e
t :time
H
*or Q 313= .9/ I A/t ;200 se# , 0 I
Design o the heating element
tRI 2 J
tI
QR
EEA
2
;200
1000313=2- 2
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9!"esign parameter #:Calculating the length of the heating element
&ormula involved/ &here/ l: length o heating element
R: resistan#e o heating element
: resisti%ity
d: "iameter o the spring
$ength/ L
36 m
*or R H/ d 11 mm/ 106Hm
! Calculating the perimeter of the nichrome spring
&ormula involved &here/ r :outer ra"ius o the heli7
Perimeter 36 mm
or r ; mm
Design o the heating element
ARL
dRL
2
6
2
1013
000131
31
r2;E1D3E2
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"esign parameter * : Calculating the no! of turns re5uired of the nichrome
spring
&ormula involved/ n (length o the spring) ? (perimeter o the heli7)
;
Although y #al#ulations &e otaine" the numer o turns to e use" as ;/ to
ha%e an assuran#e o the ee#ti%eness o the urna#e/ numer o turns a#tually
use" &as slightly ao%e 100
Design o the heating element
63
100063
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%R&'ESSES &F FABRI'A(I&N
Cutting operation:
Simple #utting &as "one y ha#.sa& an"
y &el"ing Sin#e plates &ith high
thi#.ness are "ii#ult to #ut y ha#.sa&s/
so &el"ing metho"s using high #urrent
&ere rought into a#tion
Se%eral other small #omponents li.e the
lange/ ush an" steel slee%e &ere alsoari#ate" using the lathe &ith high "egree
o pre#ision an" a##ura#y as per their
"esigns
*ig1: ,utting operation
*ig16: 5urning an" inishing
operations
Turning and facing operations: %Lathe Operation)
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%R&'ESSES &F FABRI'A(I&N
1haping and "rilling operations:
5he rough steel plates ha" to e reorme"
into ine horiKontal inishe" sura#es along
&ith re"u#tion in their thi#.ness 5he ase
plate an" the #o%er plates &ere
transorme" a##or"ingly using the shapingma#hine
Se%eral holes &ith "ierent "iameters ha"
to e "rille" into these plates an" &ere
a##omplishe" using the ra"ial "rillingma#hine
*ig1;: Shaping operation
*ig1=: Drilling operation
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%R&'ESSES &F FABRI'A(I&N
5he length o the &ire re4uire" to pro"u#e "esire"
heating is #al#ulate" an" mar.e"
5he &ire is i7e" at the t&o en"s to otain high
tension an" then &oun" aroun" the #erami# tue
&ith numer o &in"ings y .eeping them saely
apart
5hi#. layers o #erami# &ool are thruste" into the
spa#ing et&een the tue an" metalli# #asing/therey ren"ering a "e#ent insulation
*ig1: &in"ing ni#hrome
&ire aroun" #erami# tue
*ig20: ,erami#&ool insulation
;inding the heating element and Insulation:
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T2e ,riar' o6;e/ti)e 4as to *esi!n an* fa6ri/ate 2i!2
te,erat+re *eforation testin! a,,arat+s an* 2en/e t2eres+&t of t2is ,ro;e/t is a 4e&& fa6ri/ate* f+&&' f+n/tiona&< safean* ro6+st ,rotot',e1
Results
Fi!$ -#1 A/t+a& ,2oto!ra,2 of t2e entire set +, 4it2
e&e/tri/ /ir/+itr'
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Te,erat+re &e)e&s attaine* 6' t2e f+rna/e at *i=erent in,+t
/+rrent 4it2 tie$
Results!
(a
(6
(/
Fi! #"$ Te,erat+re )s1 tie ,&ots for in,+t /+rrent 8 (a -A
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>hile starting the urna#e the #urrent nee"s to e set at lo& %alues (aout
2A)
As #an e seen rom all the graphs/ higher is the input #urrent/ greater is
the initial slope o the plot Ater a signii#ant amount o time/ the slope o
the plot "e#reases an" the urna#e tries to approa#h a upper i7e"
temperature
5he #ontroller &as "esigne" to ta.e a ma7imum o =A an" thus .eeping a
margin o saety the ma7imum input #urrent &as .ept at 6A
!t &as note" that the temperature lu#tuates some&hat rom the preset
%alue on#e the #ir#uit gets #ut out 5o re"u#e this ee#t/ the #urrent &as
re"u#e" as lo& as possile eore rea#hing the parti#ular temperature
>eights up to 20.g applie" an" the stru#ture &as inta#t
"iscussions
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T2e ob)ective *as to design and fabricate a 2i!2 te,erat+re
*eforation f+rna/e1 After ana&'%in! se)era& ;o+rna& ,a,ers an*,ra/ti/a& /onstraints fa/e*# a design *as prepared1
T2e ne+t step *as to seect and design the heating eement 1Ni/2roe 4as se&e/te* an* fa6ri/ate* in t2e s,rin! for for eas'atta/2ent to t2e a&+ina t+6e1
T2en /ae t2e nee* to seect the materias1 Mi&* stee& 4as se&e/te*for str+/t+ra& /o,onents an* a&+ina 4as +se* for t2e refra/tor'/o,onents1 Cerai/ 4oo& 4as e,&o'e* to ta9e /are of ins+&ation1
An ,on-o/ rea0 mechanism 4as t2en 6ro+!2t in for te,erat+rere!+&ation an* t2en t2e entire set +, 4as fa6ri/ate* +sin! se)era&o,erations in t2e 4or9s2o,1
@2en t2e protot0pe *as brought into testing phase< it *is,&a'e*e/e&&ent ,erforan/e /2ara/teristi/s1 Mai+ te,erat+re in t2eor*er of 123 4as easi&' a/2ie)e* an* /an rea/2 si!niB/ant&'6e'on* t2at1
As ,er &oa*in! is /on/erne*< t2e set +, 2e&* its inte!rit' +,on t2e
a,,&i/ation of 43 5g oad1 It is 6e&ie)e* to 4it2stan* e)en ore1
Conclusion
0C
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T2e ost i,ortant s/o,e of f+t+re 4or9 is to actua0 do some
e+periments for 42i/2 t2e set +, 4as *esi!ne*1 I,ression /ree, testsare ,erfe/t&' s+ite* to 6e /arrie* o+t in t2e set +,1
Rest of t2e s/o,e &ies in reBnin! an* *e)e&o,in! t2e set +, for s+,erior,erforan/e
A *etai&e* ana0sis of heat osses fro t2e f+rna/e /an 6e a*e1 Int2is< 2eat &oss /oe/ients for /on*+/tion< /on)e/tion an* ra*iation /an
6e /a&/+&ate* an* t2en t2e *esi!n o*iBe* a//or*in!&'1 Soe provisions for cooing &i9e 4ater ;et /oo&in! /an 6e ,ro)i*e*
42i/2 4o+&* re+ire a**itiona& ,i,in! /ir/+itr' for t2e 5o4 of t2e /oo&ant1
An e&e/tri/ /ir/+itr' /an 6e *esi!ne* 42i/2 4o+&* 2a)e soe ana&o! to*i!ita& /on)erter /o+,&e* 4it2 ICs t2at 4o+&* enabe automated
contro )ia a P1C 2+61
Novet06 A&t2o+!2 t2is 9in* of 4or9 2as 6een *o/+ente* erst42i&e< s+/2set +,s are not /oer/ia&&' a)ai&a6&e1 A**itiona&&'< 42en t2e ,&anne*/ree, tests of soe ne4 a&&o's 4o+&* 6e ,erfore* on t2is set +,< t2eentire 4or9 4i&& !ain ne4 *iensions of no)e&t' ren*erin! t2e set +, its
in*is,ensa6&e /2ara/teristi/s1
1cope of &uture wor