Fluid Flow and Heat Transfer Modeling of AC Arc in Ferrosilicon Submerged Arc Furnace

A two-dimensional mathematical model was developed to describe the heat transfer and fluid flow in an AC arc zone of a ferrosilicon submerged arc furnace. In this model, the time-dependent conservation equations of mass, momentum, and energy in the specified domain of plasma zone were numerically solved by coupling with the Maxwell and Laplace equations for magnetic filed and electric potential, respectively. A control volume-based finite difference method was used to solve the governing equations in cylindrical coordinates. The reliability of the developed model was checked by experimental data from the previous available literature. The results of present model were in good agreement with the given data comparing with other models, because of solving the Maxwell and Laplace equations simul- taneously in order to calculate current density. In addition, parametric studies were carried out to evaluate the effects of electrical current and arc length on flow field and temperature distribution within the arc. According to the computed results, a lower power input led to a higher arc efficiency.

Physical Simulation of Hot Deformation and Microstructural Evolution for 42CrMo4 Steel Prior to Direct Quenching

Direct quenching and tempering （DQ-T） of hot rolled steel section has been widely used in steel mill for the sake of improvement of mechanical properties and energy saving. Temperature history and microstructural evolution during hot rolling plays a major role in the properties of direct quenched and tempered products. The mathematical and physical modeling of hot forming processes is becoming a very important tool for design and development of required products as well as predicting the microstructure and the properties of the components. These models were mostly used to predict austenite grain size （AGS）, dynamic, recta-dynamic and static recrystallization in the rods immediately after hot rolling and prior to DQ process. The hot compression tests were carried out on 42CrMo4 steel in the temperature range of 900-1 100 ℃ and the strain rate range of 0. 05-1 s^-1 in order to study the high tempera- ture softening behavior of the steel. For the exact prediction of flow stress, the effective stress-effective strain curves were obtained from experiments under various conditions. On the basis of experimental results, the dynamic recrystallization fraction （DRX）, AGS, hot deformation and activation energy behavior were investigated. It was found that the calculated results were in good agreement with the experimental flow stress and microstructure of the steel for different conditions of hot deformation.

Effect of External Forced Flow and Boiling Film on Heat Transfer of AISI 4140 Steel Horizontal Rod During Direct Quenching

The effects of rod falling and moving, external flow field, boiling film and radiation were investigated on fluid flow and heat transfer of AISI 4140 steel horizontal rod during direct quenching by mathematical modeling. The flow field and heat transfer in quenching tank were simulated by computational fluid dynamics （CFD） method considering falling and moving of rods during process. Therefore, modeling of flow field was done by a fixed-mesh method for general moving objects equations, and then, energy equation was solved with a numerical approach so that effeet of boiling film heat flux was considered as a source term in energy equation for solid-liquid boundary. Simulated results were verified by comparing with published and experimental data and there was a good agreement between them. Also, the effects of external forced flow and film boiling were investigated on heat flux output, temperature distribution and heat transfer coefficient of rod. Also simulated results determined optimum quenching time for this process.