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Design, Manufacturing and Testing of Induction Furnace

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Design, Manufacturing and Testing of Induction Furnace DESIGN, MANUFACTURING AND TESTING OF INDUCTION FURNACE A PROJECT REPORT Submitted by FRANCIS. T (103378044) GIPSON PEREIRA (103378049) MOHAMED ASHIQ.M (103378086) MANIVANNAN.N (103378077) in partial fulfillment for the award of the degree of BACHELOR OF TECHNOLOGY In MECHANICAL ENGINEERING BHARATHIYAR COLLEGE OF ENGINEERING AND TECHNOLOGY KARAIKAL PONDICHERRY UNIVERSITY: PUDUCHERRY 605014 APRIL 2013 1 BHARATHIYAR COLLEGE OF ENGINEERING AND TECHNOLOGY KARAIKAL DEPARTMENT OF MECHANICAL ENGINEERING BONAFIDE CERTIFICATE Certified that this project report “DESIGN, MANUFACTURING AND TESTING OF INDUCTION FURNACE” is the bonafide work of FRANCIS. T (103378044) GIPSON PEREIRA (103378049) MOHAMED ASHIQ.M (103378086) MANIVANNAN.N (103378077) who carried out the project work under my supervision. SIGNATURE SIGNATURE Prof .S.RAVICHANDRAN Mr. S . GUNABALAN HEAD OF THE DEPARTMENT SUPERVISOR Associate professor Mechanical Department Mechanical Department Bharathiyar College of Engineering Bharathiyar College of Engineering And Technology, Karaikal And Technology, Karaikal Submitted for the university examination held on.......................................... INTERNAL EXAMINER EXTERNAL EXAMINER PONDICHERRY UNIVERSITY: PUDHUCHERRY APRIL 2013 2 ACKNOWLEDGEMENT We would like to acknowledge all the people who have contributed to a great extent towards the initialization, the development and success of our project. Our sincere thanks go to Dr. Jayaraman, Principal, Bharathiyar College of Engineering & Technology, Karaikal for extending the college facilities for the successful completion of our project and for his kind patronage. We also thank Prof .S.Ravichandran, Professor & Head of the Department, Department of Mechanical Engineering, Bharathiyar College of Engineering & Technology, Karaikal for extending the excellent laboratory facilities, ideas and encouragement towards our project. We cordially thank Mr. S. Gunabalan, Associat Professor of Mechanical Department, Department of Mechanical Engineering, Bharathiyar College of Engineering & Technology for providing innovative ideas and expert guidance for the successful completion of our project. 3 4 ABSTRACT Aluminum are the important structural material in aerospace and car industries, as well as in some other areas. Their main characteristics are small specific weight, good mechanical properties, good processing and resistance to corrosion. Based on great marketing interest of Aluminum, the investigation of technological parameters of workout of Aluminum on a laboratory and pilot-plant scale is carried out. In this project a part of results on design and definition of melting, alloying and casting conditions of aluminum are presented. These investigations involve alloying temperature, alloying time, amount of alloying elements, and sequence of their adding and casting temperature on the chemical composition, microstructure and mechanical properties are investigated. 5 INTRODUCTON Metal melting is the process of producing a liquid metal of the required composition at the required rate, and with required amount of superheat while incurring the minimal cost. It is one of the most important foundry practices, as it decides the quality of the casting. There are number of methods available for melting foundry alloys such as pit furnace, open hearth furnace, rotary furnace, cupola furnace, etc. The choice of the furnace depends on several factors, primary among them are the compositional range of the material to be melted, the fuel or energy used to melt the charge, the degree of refining and control over the process and type and size of the melting unit. Induction heating is widely used in metal industry because of its good heating efficiency, high production rate, and clean working environments. The development of high-frequency power supplies provided means of using induction furnaces for melting metals in continuous casting plants. Rather than just a furnace, a coreless induction furnace is actually an energy transfer device where energy is transferred directly from an induction coil into the material to be melted through the electromagnetic field produced by the induction coil. A typical parallel resonant inverter circuit for induction furnace . The phase controlled rectifier provides a constant DC current source. The H-bridge inverter consists of four thyristors and a parallel resonant circuit comprised capacitor bank and heating coil. Thyristors are naturally commutated by the ac current flowing through the resonant circuit 6 FURNACE A furnace is a device used for heating. The name derives from Latin fornax, oven. In American English and Canadian English usage, the term furnace on its own refers to the household heating systems based on a central furnace (known either as a boiler or a heater in British English), and sometimes as a synonym for kiln, a device used in the production of ceramics. In British English, a furnace is an industrial furnace used for many things, such as the extraction of metal from ore (smelting) or in oil refineries and other chemical plants, for example as the heat source for fractional distillation columns. The term furnace can also refer to a direct fired heater, used in boiler applications in chemical industries or for providing heat to chemical reactions for processes like cracking, and is part of the standard English names for many metallurgical furnaces worldwide. The heat energy to fuel a furnace may be supplied directly by fuel combustion, by electricity such as the electric arc furnace, or through induction heating in induction furnaces. A furnace is a device that produces heat. Not only are furnaces used in the home for warmth, they are used in industry for a variety of purposes such as making steel and heat treating of materials to change their molecular structure. Central heating with a furnace is an idea that is centuries old. One of the earliest forms of this idea was invented by the Romans and called a hypocaust. It was a form of under-floor heating using a fire in one corner of a basement with the exhaust vented through flues in the walls to chimneys. This form of heating could only be used in stone or brick homes. It was also very dangerous because of the possibility of fire and suffocation. Furnaces generate heat by burning fuel, but early furnaces burned wood. In the seventeenth century, coal began to replace wood as a primary fuel. Coal was used until the early 1940s when gas became the primary fuel. In the 1970s, electric furnaces started to replace gas furnaces because of the energy crisis. Today, the gas furnace is still the most popular form of home heating equipment. Wood and coal burning furnaces required constant feeding to maintain warmth in the home. From early morning to late at night, usually three to five times a day, fuel needed to be put in the furnace. In addition, the waste from the ashes from the burnt wood or coal must be removed and disposed. 7 RAW MATERIALS Today's modern furnace uses stainless steel, aluminized steel, aluminum, brass, copper, and fiberglass. Stainless steel is used in the heat exchangers for corrosion resistance. Aluminized steel is used to construct the frame, blowers, and burners. Brass is used for valves, and copper in the electrical wiring. Fiberglass is used insulate the cabinet. DESIGN The original gas furnace consisted of a heat exchanger, burner, gas control valve, and an external thermostat, and there was no blower. Natural convection or forced air flow was used to circulate the air through large heating ducts and cold air returns to and from each room. This system was very inefficient—allowing over half of the heated air to escape up the chimney. Today's gas furnace consists of a heat exchanger, secondary heat exchanger (depending on efficiency rating), air circulation blower, flue draft blower, gas control valve, burners, pilot light or spark ignition, electronic control circuitry, and an external thermostat. The modern furnace is highly efficient—80-90%, allowing only 10-20% of the heated air to escape up the chimney. When heat is requested from the thermostat, the burners light and throws heat into the primary heat exchanger. The heated air then flows through the secondary heat exchanger (90% efficient furnace only) to the exhaust flue and chimney. The average furnace has three heat exchangers each producing 25,000 BTUs for a total of 75,000 BTUs. A flue draft blower is placed in the exhaust flue to supercharge the burners and increase efficiency. The heat exchangers perform two functions: transfer heated air from the burners to the home and allow dangerous exhaust 8 THE MANUFACTURING PROCESS 1. The primary heat exchanger is formed from two separate pieces of 409 stainless steel sheet. Each half is formed into shape by a 400 ton hydraulic press. The two halves are then fused together by a 25 ton hydraulic press. 2. The secondary heat exchanger is formed from 29-4°C stainless steel tubing and fins. The fins are welded to the tubing to form a radiator type configuration. 3. The primary heat exchanger is crimped to the secondary heat exchanger through a transition box. The flue draft blower is attached to the secondary heat exchanger. 4. The burners are constructed of aluminized steel and arrive at the plant preformed. They are then attached to a plate on the input side of the primary heat exchanger. There is one burner for each heat exchanger in the furnace. 5. The vendor supplied gas control valve is mounted to the heat exchanger and burner assembly. It is connected to the burner through a pipe. 6. The air circulation blower housing is formed through the same hydraulic press formation as the primary heat exchanger. The vendor supplied motor and squirrel cage rotor are connected and attached to the blower housing with brackets. 7. A plate is then attached for mounting the blower assembly to the heat exchanger assembly. Another mounting plate containing the vendor supplied furnace control circuitry and transformer are attached to the blower housing. 8. The air circulation blower assembly is then mounted to the heat exchanger assembly with screws and nuts. 9 9. The cabinet consists of two doors and the cabinet housing.
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