Determination of Temperature Distribution during Heat Treatment of Forgings: Simulation and Experiment

Abstract

Combination of transient computational fluid dynamics simulations of a gas-fired heat treatment furnace and experimental validation were carried out to investigate the applicability of equilibrium non-premix combustion model and the effect of different turbulence models on the thermal interactions inside the furnace. Thermal interactions analyses based on temperature measurements on an instrumented large size block were performed at different locations of the forged blocks. A good agreement, with a maximum deviation of about 4%, was obtained using a one-third periodic model of the furnace. Results indicated that the chemical equilibrium non-premix combustion model could effectively be employed for combustion modeling and subsequently products’ temperature predictions. A temperature non-uniformity of up to 331 K was determined on the surface of the forgings due to furnace geometrical design and loading pattern. Prediction of turbulence dissipation rate to turbulence kinetic energy ratio by different turbulence models could significantly affect the combustion predictions and product temperatures. Reynolds stress model was found as the most reliable turbulence model and the realizable k-epsilon model could reasonably predict the global block temperature. While, Shear stress transport k-omega model over-predicted the block temperature, it showed reasonable results in stagnation region.

Acknowledgement

The authors are very grateful to Finkl Steel, especially the R & D, Metallurgy and Engineering Departments, for providing the real-scale instrumentation and measurements used in the present research.

Disclosure statement

No potential conflict of interest was reported by the authors.

Additional information

Funding

This work was supported by the MITACS in the framework of [IT03151] grant.

Notes on contributors

Nima Bohlooli Arkhazloo

Nima Bohlooli Arkhazloo received his M.Sc. degree in the field of Energy Conversion from Iran University of Science and Technology and completed his Ph.D. in applied research in the mechanical engineering department of École de technologie supérieure (ÉTS) in 2020. His current research field is focused on optimization of large size forged block heat treatment process using CFD and experimental measurements. Also, different heat and fluid flow interactions such as radiation, turbulent combustion and their relative numerical models are his main studies.

Farzad Bazdidi-Tehrani

Farzad Bazdidi-Tehrani completed his Ph.D. degree at Leeds University, U.K. in 1991. His current research fields of interest encompass modeling of cooling techniques related to hot sections in gas turbine engines and electronic components, combined heat transfer (mixed convection–radiation) in macro and nano scales, and turbulent reactive and non-reactive flows.

Mohammad Jadidi

Mohammad Jadidi received his M.S. degree in the field of fluid mechanics in the Department of Mechanical Engineering, Isfahan University of Technology, and has completed his Ph.D. degree in Energy Conversion in Iran University of Science and Technology. His research field is related to the turbulent heat/mass transfer modeling; and turbulent complex flow modeling based on the LES and SRS techniques is the main applications of his CFD simulations.

Jean-Benoît Morin

Jean-Benoit Morin obtained his B.S. degree in metallurgy engineering from University of Quebec in 2009, and is employed by Finkl Steel-Sorel since 2010. He firstly began as Process Metallurgist and his now Metallurgy and Continuous Improvement Manager. His field of expertise is principally in steelmaking, open-die forging and heat treating of carbon and low alloy steel.

Mohammad Jahazi

Mohammad Jahazi obtained his Ph.D. from McGill University in 1989. He is the holder of the Industrial Research Chair in forming technologies of high strength alloys, CM2P at École de technologie supérieure (ÉTS). His research has been focused on the influence of thermomechanical processing parameters on microstructure evolution and the development of physics-based models for accurate prediction of material behavior during high temperature processing.