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Spray Cooling at High Temperatures
Chabičovský, Martin ; Čarnogurská, Mária (referee) ; Hajduk, Daniel (referee) ; Raudenský, Miroslav (advisor)
Spray cooling of hot surfaces is used in the metallurgical industry during continuous casting, hot rolling or heat treatment. The water is sprayed on the cooled surface by the nozzle which transforms the water stream to droplets. The spray cooling of hot surfaces can be characterized as forced convection with the presence of the boiling. This physically complicated process is influenced by many factors, such as impurities and contaminants in the water, water temperature, water flow rate, droplet size, droplet impact velocity, surface temperature, surface roughness or the presence of oxides (scales) on the cooled surface. The dominant factor that affects the heat transfer during the spray cooling is the water impingement density. Other factors have a smaller but also significant effect. This doctoral thesis deals with the influence of the water temperature, surface roughness and the presence of oxides on the intensity of the spray cooling. These factors are investigated by laboratory experiments in which the hot steel surface is spray cooled. Effect of the oxide layer is also investigated by the numerical simulation. The experimental results are theoretically explained and generalized using mathematical methods.
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HEAT – MECHANICAL DEGRADATION OF SURFACES AT THE HIGH TEMPERATURES
Zahradník, Radek ; Hajduk, Daniel (referee) ; Čecho, Ladislav (referee) ; Toman,, Zdeněk (referee) ; Raudenský, Miroslav (advisor)
The Ph.D. thesis is focused on a surface degradation mechanisms under combined heat and mechanical load. The objects of examination are work rolls from hot rolling mill which suffer such a load. In first chapter, the hot rolling process, the design, the manufacturing process and present materials of work rolls are described. The state-of-the-art study of work roll surface degradation mechanisms – wear, oxidation, thermal and contact fatigue are described in the second chapter. The characterization, the formation, the mechanisms of progression and the effects of each surface degradation mechanism is described step by step. The state-of-the-art study of analytical and numerical models which are related to hot rolling process is described in third chapter together with their limitations and flaws. The next chapters contain design of an analytical, an optimized macroscopic and a microscopic model for study of the work roll stress state. The macroscopic and the microscopic model is based on finite element method and they are implemented in ANSYS Programming Design Language. The models are used to process several case study which are based on previous experimental work of the Heat transfer and fluid flow laboratory. The results from case studies specify and expand the knowledge of work roll stress state. The results show the portion of each loading factor on the whole stress state. In addition, time and depth depended distribution of stress state is presented. The results from macrosferic model illustrate the cause of spalling and a rupture of the work roll. The results from the microsferic model show the cause of creation of the to-surface-parallel cracks within carbides of high chromium irons. Last chapter summarized of all results gathered from case studies together with the goals for further research definition. The necessary steps for further cognition are stated. The thesis contains a large set of appendixes with deeper discussion of several related topics. These appendixes represent the one third of whole the thesis.
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Boundary Conditions in the Roll Gap during Hot and Cold Rolling
Luks, Tomáš ; Pernis,, Rudolf (referee) ; Hajduk, Daniel (referee) ; Horský, Jaroslav (advisor)
Boundary conditions in the roll gap play an important role in modelling of rolling processes. In the roll gap we can observe the following: changes of rolling pressure, changes of relative velocity, influences of oxides and lubrication, etc. When taking into account all conditions mentioned above the determination of the boundary conditions is not trivial and extensive measurements are necessary. Therefore, this thesis is dealing with design of temperature and force sensors specified for the determination of friction coefficient and heat transfer coefficient in contact. The temperature sensor with an installed thermocouple measures subsurface temperature for a given depth; and then the inverse heat conduction task is used to compute temperature and heat flux on the surface. Several temperature sensors were designed and used for measuring in pilot mill and industrial rolling mill as well. The thermal responses of different sensors were compared in the numerical simulations. The inverse calculations were tested for various rolling conditions. A durability of the sensors was also studied in industrial rolling conditions. The contact stresses in the roll gap were measured by a pin, which was in direct contact with the rolled material. The forces on the top of the pin were measured by a three-axes piezoelectric force transducer and recalculated to the contact stress and friction coefficient. The sensor was implemented in a work roll and tested when rolling aluminium and steel slab for different rolling conditions. The results were compared with the integrative force sensor ROLLSURF.
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The Influence of Remaining Water and other Significant Factors on Cooling Intensity during Heat Treatment of Steel
Resl, Ondřej ; Macháčková,, Adéla (referee) ; Hajduk, Daniel (referee) ; Pohanka, Michal (advisor)
Hundreds of milions tons of crude steel are produced worldwide every year. The crude steel is further processed mainly by hot rolling. It is necesary to control cooling process during heat treatment to achieve the required mechanical and physical properties of final products. Cooling is influenced by many parameters and that is the reason why optimal cooling intensity setting is very complicated. Knowledge of the influence of individual factors is crucial for proper cooling. This work deals with the study of the influence of surface quality (surface roughness, presence of oxides) on cooling intensity and the issue of remaining water. The term remaining water means thin water layer that remains on the cooled surface after cooling. As part of the work the influence of surface roughness and oxide presence on cooling of the moving steel surfaces is experimentally investigated using different types of water cooling. To assess the impact of these parameters, cooling is investigated on three different types of surfaces (rolled, grinded, oxidized) and the results are analysed. The influence of the remaining water on cooling is also experimentally investigated. Again, the different types of water cooling and surfaces are used.
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Boundary Conditions in the Roll Gap during Hot and Cold Rolling
Luks, Tomáš ; Pernis,, Rudolf (referee) ; Hajduk, Daniel (referee) ; Horský, Jaroslav (advisor)
Boundary conditions in the roll gap play an important role in modelling of rolling processes. In the roll gap we can observe the following: changes of rolling pressure, changes of relative velocity, influences of oxides and lubrication, etc. When taking into account all conditions mentioned above the determination of the boundary conditions is not trivial and extensive measurements are necessary. Therefore, this thesis is dealing with design of temperature and force sensors specified for the determination of friction coefficient and heat transfer coefficient in contact. The temperature sensor with an installed thermocouple measures subsurface temperature for a given depth; and then the inverse heat conduction task is used to compute temperature and heat flux on the surface. Several temperature sensors were designed and used for measuring in pilot mill and industrial rolling mill as well. The thermal responses of different sensors were compared in the numerical simulations. The inverse calculations were tested for various rolling conditions. A durability of the sensors was also studied in industrial rolling conditions. The contact stresses in the roll gap were measured by a pin, which was in direct contact with the rolled material. The forces on the top of the pin were measured by a three-axes piezoelectric force transducer and recalculated to the contact stress and friction coefficient. The sensor was implemented in a work roll and tested when rolling aluminium and steel slab for different rolling conditions. The results were compared with the integrative force sensor ROLLSURF.
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Spray Cooling at High Temperatures
Chabičovský, Martin ; Čarnogurská, Mária (referee) ; Hajduk, Daniel (referee) ; Raudenský, Miroslav (advisor)
Spray cooling of hot surfaces is used in the metallurgical industry during continuous casting, hot rolling or heat treatment. The water is sprayed on the cooled surface by the nozzle which transforms the water stream to droplets. The spray cooling of hot surfaces can be characterized as forced convection with the presence of the boiling. This physically complicated process is influenced by many factors, such as impurities and contaminants in the water, water temperature, water flow rate, droplet size, droplet impact velocity, surface temperature, surface roughness or the presence of oxides (scales) on the cooled surface. The dominant factor that affects the heat transfer during the spray cooling is the water impingement density. Other factors have a smaller but also significant effect. This doctoral thesis deals with the influence of the water temperature, surface roughness and the presence of oxides on the intensity of the spray cooling. These factors are investigated by laboratory experiments in which the hot steel surface is spray cooled. Effect of the oxide layer is also investigated by the numerical simulation. The experimental results are theoretically explained and generalized using mathematical methods.
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HEAT – MECHANICAL DEGRADATION OF SURFACES AT THE HIGH TEMPERATURES
Zahradník, Radek ; Hajduk, Daniel (referee) ; Čecho, Ladislav (referee) ; Toman,, Zdeněk (referee) ; Raudenský, Miroslav (advisor)
The Ph.D. thesis is focused on a surface degradation mechanisms under combined heat and mechanical load. The objects of examination are work rolls from hot rolling mill which suffer such a load. In first chapter, the hot rolling process, the design, the manufacturing process and present materials of work rolls are described. The state-of-the-art study of work roll surface degradation mechanisms – wear, oxidation, thermal and contact fatigue are described in the second chapter. The characterization, the formation, the mechanisms of progression and the effects of each surface degradation mechanism is described step by step. The state-of-the-art study of analytical and numerical models which are related to hot rolling process is described in third chapter together with their limitations and flaws. The next chapters contain design of an analytical, an optimized macroscopic and a microscopic model for study of the work roll stress state. The macroscopic and the microscopic model is based on finite element method and they are implemented in ANSYS Programming Design Language. The models are used to process several case study which are based on previous experimental work of the Heat transfer and fluid flow laboratory. The results from case studies specify and expand the knowledge of work roll stress state. The results show the portion of each loading factor on the whole stress state. In addition, time and depth depended distribution of stress state is presented. The results from macrosferic model illustrate the cause of spalling and a rupture of the work roll. The results from the microsferic model show the cause of creation of the to-surface-parallel cracks within carbides of high chromium irons. Last chapter summarized of all results gathered from case studies together with the goals for further research definition. The necessary steps for further cognition are stated. The thesis contains a large set of appendixes with deeper discussion of several related topics. These appendixes represent the one third of whole the thesis.
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