9
Hot and warm rolling technology has been used widely to produce various metal strip products since 1880, when Japan first began steel production (Ataka, 2014). In hot rolling, the workpiece is usually heated in a furnace and the temperature decreases significantly during the subsequent slab or strip rolling process. The decreased surface temperature may cause non-uniform deformation and crack generation, especially in metals with poor plastic deformability, such as magnesium and high-silicon steel. Fischer and Yi, (1964) first proposed a rolling method with heating of the work roll to 538°C to avoid the rapid decrease in strip temperature. The advantage of rolling mills with heated equipment compared to conventional rolling mills was also discussed in detail. Cr 3 C 2 was used as the roll sleeve and steel as the main body of the work roll (Fischer and Yi, 1964). After that, methods and equipment for rolling with a heated work roll were proposed and designed by different researchers (Kang, Wang, and Lv 2005; Zhang, Wang, and Wang, 2008; Li et al., 2012) in order to avoid surface oxidation and improve the plastic deformation limit of hard- to-form materials. The preheated work roll is significantly helpful for large plastic deformation and grain refinement. Jeong and Ha (2007) discussed the influence of the work roll temperature, initial thickness, thickness reduction, rolling temperature, and rolling velocity on the microstructure and texture of AZ31 magnesium alloy during warm rolling. No cracks were found in the strip with a reduction of 30%, rolling velocity of 30 m/min, rolling temperature of 200°C, and work roll temperature of 110°C. Furthermore, the grain size was refined significantly with a single- pass 50% reduction after preheating of the work roll. Kim et al. (2014) used a preheated work roll to realize continuous high-ratio differential speed rolling, maintaining the strip temperature within an ideal range for large plastic deformation and dynamic recrystallization. This method refined the grain size of the workpiece from 11.1 m to 2.3 m. In the previous work, the resistance heating method was mainly used to heat the work roll. The lower heating efficiency of the resistance heating method causes difficulties in application to online rolling. Induction heating is widely used in hot or warm rolling processes (Lainati, 2015) because it offers high efficiency and heating rates (Davies, 1990). In order to assess the possibilities of obtaining the required parameters of induction Investigation and modelling of work roll temperature in induction heating by finite element method by L. Bao*, X-W. Qi*, R-B. Mei* , X. Zhang* , and G-L. Li An induction coil was designed successfully to heat a work roll online for hot or warm strip rolling. The surface temperature of the work roll was investigated through embedding a developed program into finite element (FE) software. A new model to describe the convective heat transfer coefficient between air and the work roll was proposed and the coefficient was obtained as a function of ambient and surface temperature. The influences of working frequency, source current density, air gap length, and coil distance on the mean and variance value of the surface temperature were investigated using the simulation results. The work roll surface temperature was significantly higher than that of the centre due to the skin effect. A longer induction heating time was beneficial for a more uniform temperature distribution on the work roll surface. The mean temperature increased exponentially with increased working frequency and coil distance. However, the mean temperature decreased with increased air gap between the coil and work roll surface. The mean value increased following a power function with increases in source current density, and increased linearly with induction heating time after the initial heating stage. A new formula was proposed and implemented to predict the mean work roll temperature based on induction heating parameters in order to control the surface temperature. The results predicted by the model agree well with measured values and the model proposed is reliable. Furthermore, the proposed equation is beneficial for calculating and controlling the value of any one influencing parameter, if the other three parameters and the ideal mean temperature of induced heating are known. finite element method, induction heating, temperature, work roll, strip rolling. * Northeastern University, Qinhuangdao, China. State Key Laboratory of Rolling and Automation, Northeastern University, China. Ironmaking Plant of Shougang Qian’an Iron and Steel Co Ltd, China. © The Southern African Institute of Mining and Metallurgy, 2018. ISSN 2225-6253. Paper received May 2017; revised paper received Dec. 2017. 735 VOLUME 118 http://dx.doi.org/10.17159/2411-9717/2018/v118n7a7

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Page 1: v118n7a7 Investigation and modelling of work roll temperature in induction heating … · 2018. 8. 13. · coil distance on the mean and variance value of the surface temperature

Hot and warm rolling technology has beenused widely to produce various metal stripproducts since 1880, when Japan first begansteel production (Ataka, 2014). In hot rolling,the workpiece is usually heated in a furnaceand the temperature decreases significantlyduring the subsequent slab or strip rollingprocess. The decreased surface temperaturemay cause non-uniform deformation and crackgeneration, especially in metals with poorplastic deformability, such as magnesium andhigh-silicon steel. Fischer and Yi, (1964) firstproposed a rolling method with heating of thework roll to 538°C to avoid the rapid decreasein strip temperature. The advantage of rollingmills with heated equipment compared toconventional rolling mills was also discussedin detail. Cr3C2 was used as the roll sleeve andsteel as the main body of the work roll

(Fischer and Yi, 1964). After that, methodsand equipment for rolling with a heated workroll were proposed and designed by differentresearchers (Kang, Wang, and Lv 2005;Zhang, Wang, and Wang, 2008; Li et al.,2012) in order to avoid surface oxidation andimprove the plastic deformation limit of hard-to-form materials. The preheated work roll issignificantly helpful for large plasticdeformation and grain refinement. Jeong andHa (2007) discussed the influence of the workroll temperature, initial thickness, thicknessreduction, rolling temperature, and rollingvelocity on the microstructure and texture ofAZ31 magnesium alloy during warm rolling.No cracks were found in the strip with areduction of 30%, rolling velocity of 30 m/min,rolling temperature of 200°C, and work rolltemperature of 110°C. Furthermore, the grainsize was refined significantly with a single-pass 50% reduction after preheating of thework roll. Kim et al. (2014) used a preheatedwork roll to realize continuous high-ratiodifferential speed rolling, maintaining the striptemperature within an ideal range for largeplastic deformation and dynamicrecrystallization. This method refined the grainsize of the workpiece from 11.1 m to 2.3 m.

In the previous work, the resistanceheating method was mainly used to heat thework roll. The lower heating efficiency of theresistance heating method causes difficultiesin application to online rolling. Inductionheating is widely used in hot or warm rollingprocesses (Lainati, 2015) because it offershigh efficiency and heating rates (Davies,1990). In order to assess the possibilities ofobtaining the required parameters of induction

Investigation and modelling of work rolltemperature in induction heating byfinite element methodby L. Bao*, X-W. Qi*, R-B. Mei*†, X. Zhang*†, and G-L. Li‡

An induction coil was designed successfully to heat a work roll online forhot or warm strip rolling. The surface temperature of the work roll wasinvestigated through embedding a developed program into finite element(FE) software. A new model to describe the convective heat transfercoefficient between air and the work roll was proposed and the coefficientwas obtained as a function of ambient and surface temperature. Theinfluences of working frequency, source current density, air gap length, andcoil distance on the mean and variance value of the surface temperaturewere investigated using the simulation results. The work roll surfacetemperature was significantly higher than that of the centre due to the skineffect. A longer induction heating time was beneficial for a more uniformtemperature distribution on the work roll surface. The mean temperatureincreased exponentially with increased working frequency and coil distance.However, the mean temperature decreased with increased air gap betweenthe coil and work roll surface. The mean value increased following a powerfunction with increases in source current density, and increased linearlywith induction heating time after the initial heating stage. A new formulawas proposed and implemented to predict the mean work roll temperaturebased on induction heating parameters in order to control the surfacetemperature. The results predicted by the model agree well with measuredvalues and the model proposed is reliable. Furthermore, the proposedequation is beneficial for calculating and controlling the value of any oneinfluencing parameter, if the other three parameters and the ideal meantemperature of induced heating are known.

finite element method, induction heating, temperature, work roll, striprolling.

* Northeastern University, Qinhuangdao, China.† State Key Laboratory of Rolling and Automation,

Northeastern University, China.‡ Ironmaking Plant of Shougang Qian’an Iron and

Steel Co Ltd, China.© The Southern African Institute of Mining and

Metallurgy, 2018. ISSN 2225-6253. Paper receivedMay 2017; revised paper received Dec. 2017.

735VOLUME 118 �

http://dx.doi.org/10.17159/2411-9717/2018/v118n7a7

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Investigation and modelling of work roll temperature in induction heating by finite element

heating, Barglik (2011) carried out three-dimensionalanalysis of electromagnetic and temperature fields in atransverse flux induction heater for thin strips using thefinite element method (FEM) and compared the calculatedresults with the measured data. Ross (2003) investigateddifferent solenoidal and transverse flux heating methods forstrip heating and discussed their application to galvanizingand strip preheating based on experimental data. The higherheating efficiency and no need to make direct contact withthe work roll are beneficial to rapid online heating and rollingprocesses. In order to optimize embossing process, a chiller-equipped heating roll system was developed by Kim et al.(2014). The work roll surface was heated by induction andthe temperature was controlled using a temperature-margin-based control algorithm and the measured temperature. Newheating equipment for the work roll using induction heatingwas designed and used in hot and warm rolling by Mei et al.(2016). Complete dynamic recrystallization occurred andultrafine grains were obtained successfully after three passesof rolling with a cold strip and the heated work roll. However,many factors have an important influence on the temperatureof the work roll, leadings to difficultly in controllingtemperature in induction heating.

Numerical simulations are widely used to solve nonlinearproblems, including thermal analysis to improve the accuracyof the predicted and controlled temperature. Localtemperature variations induced in both longitudinal andtransverse flux induction heaters were studied by Blinov etal. (2011). The temperature of a strip of AZ31 magnesiumalloy during strip rolling with a heated work roll wasanalysed based on the thermal-structural numericalsimulation (Mei et al., 2016). The temperature of the coldstrip was increased to approximately 200°C after one rollingpass under the conditions of a work roll temperature of300°C, initial thickness of 2 mm, 20% reduction, and rollingspeed of 0.1 m/s. Yu et al. (2012) discussed the changes instrip temperature during AZ31 alloy rolling with a heatedwork roll and cold strip, and proposed a new model to predictthe exit temperature of the strip. Induction heating atdifferent frequencies was investigated by FEM and thecalculated results agreed well with the experimentalmeasurements. The transient temperature field of a heatedstrip or slab was simulated based on the coupledelectromagnetic-thermal FEM (Mei et al., 2008, 2010). FEMsimulations and experiments were performed to analyse edgedefect generation in plate rolling; and it was proposed thatincreasing the temperature of the edge zone of the slab byinduction heating could reduce the possibility of corner crackformation (Pesin and Pustovoytov, 2015). Cai et al. (2013)introduced the idea of warm rolling with a work roll heatedby the induction heating method and analysed thetemperature distribution of the work roll using a 2D FE modeland the heat generation model proposed by Mei et al. (2010).

In the current work, the temperature distribution of thework roll was investigated during induction heating throughan FEM 2D coupled electromagnetic-thermal analysis, givingdetailed boundary conditions, FE mesh, and a flow chart ofthe program. The effects of various induction heatingparameters, including working frequency, air gap betweenthe coil and work roll surface, source current density, anddistance between two coils, on the temperature were studied

after changing the mean and variance of temperature basedon the simulation results. Subsequently, a new model wasproposed to predict the temperature of the work roll surfaceaccording to linear fitting and nonlinear induction, and thedata predicted by the model was compared with the resultscalculated by FEM. Lastly, the model was verified bycomparing the experimental data and simulation results. Thisstudy may be helpful in improving modelling methodology tosimulate the work roll temperature in induction heating andaccurately control it during roll processing.

The parameters of the work roll were the same as those of theexperimental rolling mill used to analyse induction heating(Figure 1). The induction coil consisted of a copper pipeforming a single circle on the work roll surface, with a cross-sectional area of 20 mm2. A magnetizer was installed at theoutside of the coil (Figure 1a) to improve the magnetic fieldand heating efficiency. The material of the work roll was hotdie steel (CG-2), whose properties are assumed constant(free-space permeability 4 ×10−7 H/m (Mei et al., 2008),expansion coefficient 13.1×10–6 °C−1 (Xu and Chen, 2001),and density 7900 kg/m3 (Xu and Chen, 2001)) for thepurpose of analysing the electromagnetic-thermal field. Therelative permeability values of the air and the coil were set tounity (Mei et al., 2008). The effects of temperature on themain electromagnetic-thermal properties (Xu and Chen,2001) are given in Table I. In order to ensure an adequateservice life and reduce the elastic deformation, the work rollis usually not heated to high temperature (Fischer, 1964).Therefore, these properties are given for temperatures lessthan 700°C, and those at temperatures of 740 to 1200°C canbe obtained by linear extrapolation. The relative permeabilityof the steel changes to approximately unity by thermaldemagnetization when the temperature reaches the Curietemperature of about 740°C (Xu and Chen, 2001). After this,the relative permeability decreases slowly to reach 1.0 at1200°C (Xu and Chen, 2001; Mei et al., 2008). The initialtemperature is set to 20°C. The induction heating parameterschosen to analyse the effects on temperature were: workingfrequency 5–100 kHz; current density 5.0×106 to 1.5×107 A/m2; air gap between coil and work roll surface 5–30 mm; and coil conductor spacing 30–180 mm. The velocityof the work roll was set to 0.05 m/s and the consumed timewas set to one rotation of the work roll.

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Only the change of surface temperature was calculatedduring induction heating, and the boundary conditionsincluded convective and radiative heat dissipation. Therefore,the heat transfer coefficient is written as

[1]

where h (W/m2K) is the total heat transfer coefficient, whilehrad (W/m2K) and hconv (W/m2K) are the heat transfercoefficients in the radiative and convective processes,respectively. The surface temperature of the work roll and theambient temperature affect the heat transfer coefficient inradiative processes; the radiative heat transfer coefficient canbe described as

[2]

where Twr (K) is the surface temperature of the work roll, Tair(K) is the air temperature, and is the Stefan–Boltzmannconstant, 5.67×10−8 W/m2K4. The surface emissivity (Zhou,2003; Han, Lee, and Kim, 2002) is described as

[3]

As forced convection is ignored because of the low speedof the work roll (Panjkovic, 2007), the heat transfercoefficient of natural convection can be written as (Dai,2005)

[4]

where g (m/s2) is the gravitational acceleration, d (m) thecharacteristic size (in this case equal to the work rolldiameter), Pr the Prandtl number, (K−1) the coefficient ofexpansion, (m2/s) the kinematic viscosity, and (W/m K)the conductivity of air at a characteristic temperature, in thiscase set to about 350°C (Dai, 2005). Referring to theequation given by Panjkovic (2007), and for an assumedmean value of characteristic temperature of air around thework roll surface, the convective heat transfer coefficient canbe described as

[5]

One cycle of the square induction coil is designed to heat thework roll. The experimental equipment was designed and theexperiments were carried out in a similar fashion. The lengthof the coil in the axial direction of the work roll was largerthan the radius, so the influence of the coil along the circular

direction on the induction heating can be neglected.Accordingly, a 3D FE model can be simplified to a 2Dproblem to reduce the computational time. The distancebetween adjacent coil conductors in the axial direction isreferred to here as the coil distance. The induction current isgenerated when the source current passes through the coil,which then heats the work roll. In Figure 1b, the red elementsexpress one circular movement of the coil, whereas the forkand point are used to describe the source current direction ata given time during induction heating. The quadrilateralelements in the mapped mesh model provide higher solutionprecision than triangular elements in a free mesh model.Therefore, the outside of the work roll is modelled using amapping mesh with quadrilateral elements, while the centreis modelled as a free mesh with quadrilateral elements.Furthermore, the skin depth should have been divided intothree or four layers of elements to improve the predictedprecision. However, in order to reduce the computationaltime, these elements were meshed more coarsely from thecentre to the boundary (Figure 1b). There were a total of 10122 elements and 30 427 nodes in the FE mesh, with thenumbers of elements and nodes for the work roll being 9782and 28 807 respectively.

The skin depth is greatly affected by the workingfrequency, resistivity, and permeability (Davies, 1990; Blinovet al., 2011), which can be expressed as

[6]

where is skin depth, is relative permeability, 0 is free-space permeability, and ƒ the working frequency.

The interaction of the electromagnetic field with the thermalcharacteristics impedes the solving of the coupledelectromagnetic-thermal field during induction heating. Thetemperature distribution has a significant effect on themagnetic properties of the material, which then generatesdifferent electromagnetic fields. Meanwhile, differentinduction currents give rise to different Joule heating effects.In addition, the relative positions of the induction coil andwork roll surface change with the rotation of the work roll.

The electromagnetic-thermal model was developed in theANSYS software environment, which employs an iterativesolver to solve for the temperature and electromagnetic field.In order to solve problems for the rotation of the work roll byFEM, the induction coil was assumed to have the samevelocity as the work roll, but in the opposite direction, and

Investigation and modelling of work roll temperature in induction heating by finite element

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Table I

Conductivity (W/m·K) 34.3 33.4 33 32.6 32.2 31.8 31.4 29.8Heat Capacity (J/kg·K) 572.6 585.2 605 652.0 710.6 794.2 948.8 820Resistivity (10−6 Ω·m) 0.48 0.63 0.77 1.01 1.14 1.22 1.29 1.65Temperature (°C) 20 200 300 400 500 600 700 740 1200Permeability (10−6 N/A2) 251.2 256.2 268.8 288.1 347.3 392.8 439.2 1.26×10-6 1.26×10-6

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the work roll was assumed to be stationary. During inductionheating, the movement of the source current causes the heattransfer boundary to change. Therefore, the transienttemperature should be solved with different positions of thesource current and boundary conditions through embeddingthe appropriate programs in the software.

The flow chart of the coupling methodology is shown inFigure 2. Firstly, the geometry and FE mesh were createdaccording to the input parameters, including materialsproperties, element type, and heating parameters. A series ofarrays for storage was defined and the number of elementsand nodes on the surface of the work roll were reordered inorder to simulate the rotation of the work roll, change of theboundary conditions, and loads. Secondly, the inductionheating parameters were set and saved in the generatedelectromagnetic physics environment. Then the thermalanalysis parameters for the elemental model of the work rollin the thermal physics environment were set and saved. Inthe solution of the electromagnetic field at ti+1, thetemperature at ti was used to calculate the electromagneticproperties and the Joule heat was obtained for the solution ofthermal analysis at ti+1. When the FTIME meets the settingvalue, the simulation has finished.

Figure 3 shows the temperature distribution at differenttimes, with an air gap of 10 mm, coil distance of 80 mm,source current density of 7.5×106 A/m2, and workingfrequency of 50 kHz, where MX and MN are expressed as themaximum and minimum values of the temperature,respectively. The position of maximum temperature changeswith the rotation of the work roll. The temperature of therotating work roll during induction heating was predicted

through the developed program-coupled FE model. Themaximum temperature occurred in the same region after onerotation, and the skin effect creates a significantly highertemperature at the surface than the centre. The layerdistribution of the temperature caused by induction heatingis beneficial for maintaining the strip temperature. Withincreasing induction heating time, the centre is heated byconduction. The temperature at positions closer to theinduction coil increased quickly, and the temperaturedifference was obvious among these surface nodes. Thesurface temperature changed from 32°C to 88.8°C after onerotation and varied from 327°C to 394°C at 1200 secondsunder the above specified conditions.

Both the distribution and homogeneity of the surfacetemperature have an important influence on the strip rollingprocess. In order to study the change in temperature withdifferent induction parameters, ignoring edge effects, themean temperature Ta and variance temperature ST

2 of thenodes in the work roll surface were used to describe theheating efficient and homogeneity (Marck et al., 2012)

[7]

where n is the number of nodes on the work roll surface. Inthis study, eight nodes, including the typical nodes of A, B, C,and D (Figure 3f) and four others in the middle (E, F, G, andH), were selected to analyse the mean value andhomogeneity.

The change in Ta and ST2 with induction heating time is

shown in Figure 4. It was found that the coefficient ofdetermination was 0.9985 and that ST

2 increased

Investigation and modelling of work roll temperature in induction heating by finite element

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exponentially with heating time. ST2 increased by 90 seconds

from 60 seconds to 300 seconds, but only by 10 secondswithin the range of 900 seconds to 1200 seconds. Thisindicated that ST

2 increases more slowly with increasedinduction heating time. The Ta value increased significantlywith the induction time, with an approximately linearrelationship. Ta was approximately 155°C at 300 seconds and335°C at 1200 seconds. Therefore, a lower temperature at ashorter induction time can be used for rolling with a hot strip.Meanwhile, the higher temperature after a longer inductiontime can easily meet the requirements for heat transfer fromthe heated work roll to a cold strip. Furthermore, the fitting

curves show the coefficients of determination to be 0.9787 ifthe data point at Ta at 300 seconds is included, and 0.9973without the data point. The ST

2 value increases more slowlythan Ta with increased time, contributing to the homogeneityof the surface temperature.

Due to the lower homogeneity early in heating, the effects ofthe induction heating parameters on induction heating after300 seconds were studied. The induction heating parameters,including the working frequency fw (kHz), air gap ga (mm)between coil and work roll surface, source current density cs(MA/m2), coil distance dc (mm) in the circumferentialdirection between the two coils, and the heating time haveimportant influences on the changes in Ta and ST

2 .

Figure 5 shows the influence of fw on the Ta and ST2 values of

the surface temperature. A higher working frequency createda more significant skin effect and higher inductive currentintensity. Ta increased exponentially with increased workingfrequency. The minimum of determination coefficients of fitcurves was greater than 0.999. Consequently, the fittingmodel is valid. The mean temperature changed very slowly at500 Hz. However, as the induction heating time increasedfrom 300 seconds to 1200 seconds, the mean temperatureincreased significantly from 220°C to 550°C at 100 kHz. In

Investigation and modelling of work roll temperature in induction heating by finite element

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Investigation and modelling of work roll temperature in induction heating by finite element

addition, with increasing working frequency, ST2 first

increased slowly from 500 Hz to 10 kHz, before increasingmore quickly from 10 kHz to 100 kHz. The induction heatingtime has less influence on ST

2 than fw. Despite the highervariance value, the ratio of the maximum temperaturedifference to the mean value decreased significantly withincreased working frequency. Therefore, a higher workingfrequency is beneficial for the homogeneity of surfacetemperature.

The effect of ga on Ta and ST2 is shown in Figure 6. Ta

decreased exponentially with increasing air gap length. Theminimum of coefficient of determination was 0.99947,demonstrating that the fitting curves were effective. Increaseddistance from the coil to work roll surface decreased theintensity of the magnetic induction current and Ta decreasedwith increasing ga. However, the magnitude of increase wasdifferent and a smaller ga caused a stronger increase in Ta.As an example, the magnitude of increase was 100°C with achange of ga from 10 mm to 20 mm, and 50°C with a changeof ga from 20 mm to 30 mm. The ST

2 value of the surfacetemperature decreases markedly with increased ga anddecreased induction heating time. ST

2 changes less at 1200seconds than at 900 seconds with ga = 5 mm because of thehigher temperature. Therefore, smaller ga values and longerinduction heating times promote homogeneity.

The influence of cs on the Ta and ST2 values of surface

temperature is shown in Figure 7. Ta varied as a power

function. The minimum coefficient of determination was0.9993. A higher induction current intensity results fromhigher cs, so Ta increased significantly with increases of cs.The ST

2 value of the surface temperature increased

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exponentially with increasing cs. ST2 increased slowly in the cs

range from 5.0 MA/m2 to 10.0 MA/m2, but for furtherincreases in cs to 15 MA/m2, ST

2 increased to approximatelyfour times the value at 10.0 MA/m2. Thus, the surfacetemperature became more homogeneous with increasedheating time because the increase in ST

2 was less than that of Ta.

The value of dc can be controlled by changing the number ofinterval elements (Figure 1b). The influence of dc on Ta andST

2 of the surface temperature is shown in Figure 8, with theminimum value of the coefficient of determination being0.99996. Ta increased significantly with increases in dc. Thiswas mainly because the reversed direction of the sourcecurrents for elements i and i+1 (Figure 1) generates aninduction current with a reversed direction. The interaction ofthe reversed induction current decreased the current intensityin the effective regions of the electromagnetic fields. The ST

2

value increased initially for dc values below 80 mm, butdecreased within the range of dc from 80 mm to 180 mm.Clearly, larger dc values benefit the homogeneity of thesurface temperature. Furthermore, the surface temperaturehad a nearly constant ST

2 with dc = 130 mm.

In order to predict Ta, a new function was proposed accordingto the curves in Figures 5 to 8. Ta varied exponentially withthe air gap, coil distance, and working frequency, whilevarying according to a power law with increased sourcecurrent density. Therefore, the function is described as

[8]

where A0, B0, C0, D0, E0, C1, D1, and E1 are constants.Taking the natural logarithm of both sides of Equation

[8] gives:

[9]

The values of C1, D1, and E1 are 0.1, –1, and 0.5,respectively, according to the linear fitting precision of theplots of ln(Ta)–(fw)C1, ln(Ta)–(dc)D1, and ln(Ta)–(ga)E1.

Then, the values of B0, C0, D0, and E0 can be obtained as:

[10]

The values of the constants B0, C0, D0, and E0 wereobtained as 1.748, 4.854, -35.663, and –0.231, respectively,from the mean slope of the lines in the plots of ln(Ta)–(fw)0.1,ln(Ta)–ln(cs), ln(Ta)–(dc)–1, and ln(Ta)–(ga)0.5 (Figure 9). Tais therefore described as:

[11]

Subsequently, substituting different source currentdensities, work frequencies, coil distances, and air gaps intoEquation [11] with different induction heating timesprovided the constant A0 as equal to the slope of the fittingcurves, as shown in Figure 10. It can be seen that A0decreased linearly with increased induction heating times.Through the linear fitting, the value is described as:

[12]

Investigation and modelling of work roll temperature in induction heating by finite element

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Investigation and modelling of work roll temperature in induction heating by finite element

According to the above analysis, the model obtained forTa in induction heating can be deduced as:

[13]

where t (s) is the induction heating time.The temperatures calculated by the new model and

ANSYS software were compared to validate the modelpredictions (Figure 11). The new predicted temperatureagreed well with that obtained using the ANSYS software,with the coefficient of determination being 0.99301. Thus,the model proposed and obtained from the FEM data reliablypredicted the temperature of the work roll in induction

heating. The nonlinear analysis method is suitable for thesolution of induction heating and constructing themathematic model.

Furthermore, the modelling technique and methods arehelpful for nonlinear analysis of engineering problems. Forthe known values of the working frequency, air gap, coildistance, and source current density during inductionheating, the mean temperature at any time can be predictedby the model. Furthermore, Equation [13] can be used tocalculate the critical value of any one influencing parameter ifthe other parameters and the ideal mean temperature ofinduction heating are known. As an example, when the airgap is 10 mm, the source current density is 10 MA/m2, coildistance is 100 mm, and ideal mean temperature is 300°C,the working frequency should be approximately 40 kHz forheating time of 450 seconds according to the model.Induction heating experiments have been also carried out toverify the model predictions with the same conditions as inthe above example. The relationships between the criticalworking frequency and idea temperature, mean measuredvalue, and predicted results are shown in Figure 12. In orderto reduce error, the position located between typical points Dand H was measured rapidly five times in 15 seconds and themean value recorded. The five measurements for the aboveexperimental conditions were 318°C, 321°C, 319°C, 323°C,and 324°C, and the relative error of these measured valueswas less than about 2%. Additionally, different experimental

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parameters were also selected as follows to verify the model:the source current was set to 7.5 MA/m2, working frequencywas set to 25 kHz, the air gap was 30 mm, and the coildistance was 80 mm, with heating time from 300 seconds to3600 seconds (Figure 12b). It can be seen that thetemperature predicted by the proposed model was in goodagreement with the measured value. The maximum error wasabout 12.4% and the average relative error was 3.9%.Therefore, the model derived from the FEM data is useful forpredicting the temperature of the work roll in inductionheating.

A program was developed and embedded into the FEsoftware ANSYS to simulate the surface temperature of thework roll for metal strip rolling during induction heating. Theskin effect created a higher temperature at the surface thanthat at the centre. The variance value increased exponentiallywith increased heating time. The mean temperature variedapproximately linearly after the initial heating stage ofapproximately 300 seconds.

With increased working frequency, current density, andcoil distance, and decreased air gap, the mean temperatureincreased exponentially. Furthermore, the variance valueincreased with increasing source current density and workingfrequency and decreasing air gap. However, the variancevalue first increased and then decreased with increasing coildistance, because of the change of the electromagnetic field.Despite the increased variance value of the surfacetemperature, longer induction heating times promotedtemperature homogeneity because the surface temperaturechanged more dramatically than the variance value.

The relationship between the mean temperature andinduction parameters was fitted according to the simulateddata. A new formula was developed to predict the meantemperature of the work roll during induction heating,considering the working frequency, air gap, coil distance,source current density, and induction heating time.Furthermore, the formula could be used to calculate thecritical value of any one parameter, given the influencingparameter with three known values and the ideal meantemperature of induction heating. The predicted resultsagreed well with the simulated data by FEM and themeasured values from actual induction heating experiments.

The authors gratefully acknowledge the financial supportfrom the Natural Science Foundation - Steel and IronFoundation of Hebei Province (no. E2014501114 andE2018501016), Fundamental Research Funds for the CentralUniversities (No. N172304042), the Doctoral ScientificResearch Foundation of Liaoning Province (No.20170520314), and the Science and Technological YouthFoundation of Hebei Higher Education (no.20132007 andQN2016301 )

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Investigation and modelling of work roll temperature in induction heating by finite element

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