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Research Papers

An Approach to Heat Transfer Analysis of Wire Loops Over the Stelmor Conveyor to Predict the Microstructural and Mechanical Attributes of Steel Rods

[+] Author and Article Information
Ishant Jain

Raychem Innovation Center,
Halol, Gujarat 389350, India
e-mail: ishantmiet@gmail.com

Shaumik Lenka

Tata Steel Limited,
R&D Building, Jamshedpur,
Jharkhand 831007, India
e-mail: shaumik.lenka@tatasteel.com

Satish Kumar Ajmani

Tata Steel Limited,
R&D Building, Jamshedpur,
Jharkhand 831007, India
e-mail: skajmani@tatasteel.com

Saurabh Kundu

Tata Steel Limited,
R&D Building, Jamshedpur,
Jharkhand 831007, India
e-mail: saurabh.Kundu@tatasteel.com

Contributed by the Heat Transfer Division of ASME for publication in the JOURNAL OF THERMAL SCIENCE AND ENGINEERING APPLICATIONS. Manuscript received March 5, 2015; final manuscript received January 26, 2016; published online March 1, 2016. Assoc. Editor: W. J. Marner.

J. Thermal Sci. Eng. Appl 8(2), 021019 (Mar 01, 2016) (11 pages) Paper No: TSEA-15-1065; doi: 10.1115/1.4032709 History: Received March 05, 2015; Revised January 26, 2016

To understand and predict the microstructure evolution in various grades of steel, a heat transfer coupled with phase transformation model has been formulated with an enhanced stelmor cooling module. This module is capable of handling both blower assisted high cooling and retarded cooling using hoods. The stelmor module incorporates the change in ring spacing of the wire loops on the stelmor due to a change in mill speed and conveyor speed of the wire rod mill. A geometrical approach to convective and radiative losses taking into account the void fraction and shape factor of wire loop is reported. This makes the model robust by strengthening the heat transfer formulation. This paper deals with the correlation of wire rod mill process parameters on the cooling curve of wire rods. The cooling of wire rods is dependent on the stelmor operating parameters. Commercial high carbon grades require high capacity blowers for efficient cooling to refine the pearlite microstructure and impart greater strength. Welding grade wire rods (low carbon grades) on the other hand require retarded cooling to increase the ferrite grain size and decrease the ultimate tensile strength.

Copyright © 2016 by ASME
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References

Figures

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Fig. 1

Schematic of the stelmor conveyor layout for a wire rod mill

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Fig. 2

Wire loop schematic on a stelmor conveyor during high carbon wire rod rolling

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Fig. 3

Wire loop schematic on a stelmor conveyor during low carbon wire rod (electrode grade) rolling

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Fig. 4

Cross section schematic of wire loop

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Fig. 5

Top view of the wire section over the stelmor conveyor

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Fig. 6

Schematic of the third quadrant of the wire loop

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Fig. 8

Enclosed volumes between wire sections 1, 2, and 3

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Fig. 9

The finite element mesh for the heat transfer and phase transformation model

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Fig. 10

Validation of cooling curve predicted using model with the measured values for an 8 mm high carbon wire rod

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Fig. 11

Validation of cooling curve predicted using model with the measured values for a 5.5 mm high carbon wire rod

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Fig. 12

Comparison of heat transfer coefficient of Campbell et al. [911] and stelmor model incorporated in the thermomechanical rolling simulator for the 3-9 O'clock positions

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Fig. 13

Comparison of heat transfer coefficient of Campbell et al. [911] and stelmor model incorporated in the thermomechanical rolling simulator for the 6-12 O'clock positions

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Fig. 14

Model predicted cooling profile at the 3 and 9 O'clock positions with respect to dwell time on the conveyor for a 5.5 mm high carbon wire rod

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Fig. 15

Model predicted cooling profile at the 6 and 12 O'clock positions with respect to dwell time on the conveyor for a 5.5 mm high carbon wire rod

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Fig. 16

Model predicted cooling profile at the 3 and 9 O'clock positions with respect to distance on the conveyor for a 5.5 mm high carbon wire rod

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Fig. 17

Model predicted cooling profile at the 6 and 12 O'clock positions with respect to distance on the conveyor for a 5.5 mm high carbon wire rod

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Fig. 18

Scanning electron microstructure of pearlite for trial 2 at: (a) the 6–12 O'clock positions and (b) the 3–9 O'clock positions

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Fig. 19

Cooling profile for retarded cooling of the low carbon electrode quality wire rods for the 3-9 O'clock and 6-12 O'clock positions. The points marked A and B show the ferrite transformation finish and pearlite transformation start for the 3–9 O'clock positions and the 6–12 O'clock positions, respectively.

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Fig. 20

Ferrite–pearlite microstructure of the low carbon electrode grade wire rod produced by retarded cooling on the stelmor

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