final presntation new22

7/24/2019 Final Presntation New22

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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 +,


7/29

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


10/29

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


11/29

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


12/29

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


v

2 ld

D

1D00E03=0E1D3E22B1 2

val lRR

al)( 2

1

2

2 -

100)10260(1330 22 0.0-

al

al


16/29

$.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@


Tcm aa F

;0000110 TF

Tcmalal

FEE

;00==020

Tcm F

;00E=6DE0B030


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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


tRI 2 J

tI

QR

EEA

2

;200

1000313=2- 2


18/29

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


ARL

dRL

2

6

2

1013

000131

31

r2;E1D3E2


19/29

"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


63

100063


20/29

%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)


21/29


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


22/29


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:


23/29

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'


24/29

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


25/29

>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

final presntation new22

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