Prediction of Life Cycle of Induction Furnace Wall for Silica Ramming Mass

Abstract

Casting process involves melting for metals in closed vessel called Furnace. Induction furnaces are using principle of electromagnetics so any kind of fuel is not required. The problem is low cycle thermal fatigue failure of induction melting furnace wall. It is having micro cracks and it loses its thermal and mechanical properties. It creates problematic situation to ongoing production cycle. Life cycle varies depending upon size and geometry of induction furnace, change in application, material which is to be melted, worker’s ability and skills, scrap material used for melting, etc. It is only possible to predict life cycle of induction furnace wall by various experimental work for different cases. There is no standard or reliable theory which can predict life cycle of induction furnace wall till date. In this paper, an innovative algorithm is developed which can predict the life cycle of induction furnace wall with very high accuracy. The induction melting furnace wall is made up of ceramic based silica ramming mass. The failure of furnace wall occurs due to creation of reversible cyclic thermal stresses by heating and cooling cycles. Temperature field and thermal stress field of the induction furnace wall are calculated by using explicit finite difference method based on the physical explanation of its damage under low cycle thermal fatigue conditions. The life time of the furnace wall is found out by means of critical thermal stresses created inside the wall of induction furnace from modified S – log N Curve.