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Journal of the Brazilian Society of Mechanical
Sciences
Print version ISSN 0100-7386
J. Braz. Soc. Mech. Sci. vol.21 no.4 Rio de Janeiro Dec. 1999
http://dx.doi.org/10.1590/S0100-73861999000400008
A Temperature Predicting Model for
Manufacturing Processes Requiring
Coiling

Nando Troyani
Luis Montano
Universidad de Oriente
Departamento de Mcanica
Puerto de La Cruz Venezuela


Abstract
A model for predicting temperature evolution for automatic
controling systems in manufacturing processes requiring the
coiling of bars in the transfer table is presented. Although the
method is of a general nature, the presentation in this work
refers to the manufacturing of steel plates in hot rolling mills.
The predicting strategy is based on a mathematical model of
the evolution of temperature in a coiling and uncoiling bar
and is presented in the form of a parabolic partial differential
equation for a shape changing domain. The mathematical
model is solved numerically by a space discretization via
geometrically adaptive finite elements which accomodate the
change in shape of the domain, using a computationally novel
treatment of the resulting thermal contact problem due to
coiling. Time is discretized according to a Crank-Nicolson
scheme. Since the actual physical process takes less time
than the time required by the process controlling computer to
solve the full mathematical model, a special predictive device
was developed, in the form of a set of least squares
polynomials, based on the off-line numerical solution of the
mathematical model.
Keywords: Temperature Prediction, Thermal Contact, Finite
Elements, Metal coiling


Work partially supported by Consejo de Investigacin, Universidad de
Oriente, Venezuela and CEGELEC Automation Inc., Pittsburgh, PA, USA
A streamlined version of this work appeared in the Proceedings of the 3d
International Conference on Adaptive Computing in Design and
Manufacturing. Plymouth, UK, 1998.

Introduction
In order to minimize heat loss to the environment in the transfer table (the
stage between rougher rolling stands and finishing rolling stands in a hot
mill) and for reasons of energy consumption, metallurgical uniformity and
rollability, a variety of heat loss reducing strategies have been employed.
One of the utilized strategies is provided by the Coilbox (Smith,1981) a
Stelco Inc. patent, which has been succesfully used in some industrial
instalations worldwide. By means of this device the hot bar coming out of
the rougher is coiled and uncoiled, Fig. 1, prior to processing it in the
finisher, resulting in a substantial heat loss rate reduction, due to the fact
that once coiled the bar surfaces no longer "see the environmental
temperature", except for the edges, and as a result the radiating heat to the
environment is practically eliminated, and the convected heat is substantially
reduced. To preset the parameters of the finishing rolling stands in order to
make the finishing process more accurate and efficient it is necessary to
have an estimate of the temperature distribution along the bar prior to
rolling it.


Fig. 1 Finite element discretization and coordinate sytems in a partially coiled
bar.

Here, a description of the mathematical model of the process is given. The
reader is referred to Troyani (1996) for additional details, including the
variational formulation of the problem and the corresponding temperature
finite element representation and solution. Since the bar curves and
straightens out during coiling and uncoiling elements with geometric
adaptability were used, such as the 8-node isoparametric element (Becker,
Carey and Oden, 1981). Based on the numerical solution of the
mathematical model of the heat transfer process, an on-line fast
temperature prediction system (OFTPS) was developed and is presented in
this work. The OFTPS is a necessary device since the actual physical process
of coiling and uncoiling takes less time than the numerical solution of the
mathematical model for the particular computers used to run the software
for automatic control of hot mills.
The model accounts for the different speeds of the Coilbox operation during
both coiling and uncoiling, Fig. 2. This is considered a critical issue since this
aspect of the operation directly affects the time of exposure of the different
segments of hot bars to the environment, and as a result it affects the heat
transfer process.


Fig. 2 Typical bar speed schedule according to the coiling device operating
procedures

The mathematical model for the problem is stated in section 2. It consists of
the non-linear parabolic partial differential equation of heat conduction
together with the non-linear convective and non-linear radiative boundary
conditions, initial conditions in the form of an initial distribution of
temperature, as well as the equations which describe the motion and change
of shape of the bar as it coils and uncoils. In section 3 the equations
describing the motion of the bar are given together with a brief description
of the operation of a coiling device in terms of its operational speeds.
In order to accomodate the shape changing domain of the bar the model is
solved using geometrically adaptive finite elements for the space
discretization. Time discretization was achieved via a Crank-Nicolson scheme
(implicit parameter value of 0.5). The solution proceeds in a forward time
stepping manner with a variable time step in order to comply with the coiling
process variable speed schedule. The problem was treated as a first
approach as two dimensional.
Special attention was given to the issue of continuosly changing boundary
conditions due to thermal contact. The novel numerical treatment given to
the thermal contact problem which arises as a result of adjacent coiling
wraps coming into contact is described in section 4.
The numerical results for a 0.0254 m thick, 85.34 m long steel bar as well as
a full decription of the OFTPS are given in sections 5 and 6 respectivelly.

The Mathematical Model
The equation governing the temperature evolution in the bar is the well
known non-linear parabolic partial differential equation of heat transfer by
conduction (Ozisik, 1993) given by:

(1)

Nomenclature
c ( T ) = temperature
dependent heat capacity, [
J / kg K]
C = capacitance matrix
containing the heat capacity
and density dependency
f = thermal load vector in
the global system
h = film heat transfer
coefficient, [W / m
2
K]

k ( T ) = temperature
dependent thermal
conductivity, [W / m K]
K = stiffness matrix for the
problem
N = element number of
nodes
R = radial coordinate
T = temperature, [K]

T = temperature nodal
vector
T = polynomially calculated
temperature
t = time, [s]
u = speed function, [m/s]
= for all
x = space coordinate, [m]


Greek symbols
e = belongs to
o = bar thickness
|( x ) = space dependent
element shape function
cO ( t ) = time dependent
bar boundary
( T )= temperature
dependent material density,
kg/m
3

V = vector differential
operator
A = increment of
u = total arc of angle of
bar
O ( t ) = time dependent
bar domain
Subscripts
c = convective
cr = convective plus
radiative
tccf = thermal contact
conductance film
coefficient
r = radiative
1,2 = coordinate directions
= variable taken at a
sufficient distance
Superscripts
* = initial
o = initial value of a given
variable

The boundary condition is the combined convective and radiative boundary
conditions given by

(2)
where , .The indicated derivative represents the outward
normal derivative. The indicated film coefficients are computed in the actual
calculations using standard established heat transfer procedures for
convective and equivalent radiative film coefficients, (Ozisik, 1993).
With an initial distribution of temperature , an initial condition is assumed
in the form:

(3)
The numerical solution of the parabolic mathematical model was achieved
via a single time stepping procedure using a space discretization through
finite elements. Due to time dependency of the problem the approximating
element equations include time dependent nodal temperature values as well
as space dependent shape functions as indicated below in Eq.(4)

(4)
when Eq.(4) is used to give approximate representation to the temperature
field in each element and using Eq.1 the following form of the global system
of ordinary differential equations results

(5)
Discretization of the time derivative in Eq.(5) was resolved using a standard
Crank-Nicolson implicit scheme with an impliciticity parameter value of 0.5.
The solution proceeds in a forward time stepping manner with a variable
time step in order to comply with the coiling process and uncoiling process
variable speed schedule.
In order to satisfy curving of the bar during coiling the 8-node isoparametric
element was used (Becker, Carey and Oden, 1981).

Motion of the Bar
The bar beeing hot rolled is required to move according to specific mill
operating speeds. If in addition coiling of the bar is required in the transfer
table, then the bar will be complied to move according to the coiling device.
Figure 2 exhibits a typical speed schedule of a bar coiling device showing
fifteen stages (each of the straight line segments). As an illustration it is
indicated that the first stage corresponds to the speed coming out of the
rougher set of stands. The second stage coresponds to deceleration of the
bar to the coiling device threading speed. The third stage is a short constant
speed stage. The fourth corresponds to acceleration of the bar to full coiling
speed. And so on.
There are two distinct types of motion of the bar in the transfer table.
Straight motion prior to coiling and after uncoiling, and curving and
uncurving during coiling and uncoiling. Coiling in our case implies that all bar
points (element nodes computationally) move so that the bar adopts a spiral
shape.
These motions are fully described mathematically with the following
equations based on the coordinate systems of Fig. 1.
1. Prior to any coiling the motion of the bar points is straight and is given
by:

(6)

(7)
and represent initial coordinate value of bar points and speed
function respectively.
2. Once coiling starts the motion is given by:
2.1 The _
l
coordinate of points which have yet to be coiled change according
to expression in Eq.(6) above
and the coordinate changes according to:

(8)
represents the total angle of arc of coiled bar up to time t, and o the
thickness of the bar.
2.2 Points which have coiled ( crossed line _
1
= 0 at least once ), and here for
simplicity the switch is made to cylindrical coordinates, move according to:

(9)

(10)
where r(t) is given by the following expressions:
for points on the inner surface of the wraps

(11)
for points on the middle plane of the wraps

(12)
for points on the outer surface of the wraps

(13)
r
0
represents the radius of the bar point closest to the center of the coil.
3. Position of the coiled bar for uncoiling is achieved by the following 180
rotation:

(14)a

(14)b
4. Uncoiling is controlled by expressions similar to those in numerals 1 and 2
above.
The Lagrangian approach is used to keep track of the evolving temperature
field in a moving and shape changing domain according to expressions in
Eq.6 through 14.

The Contact Problem
Of major concern in the model is the numerical handling of the thermal
contact which arises as a result of adjacent wraps coming into contact during
coiling and losing contact during uncoiling. This issue which appears in many
applications has been treated in a number of different ways by various
authors, Nakajima (1995), Sridhar and Yovanovich (1996) and Tseng and
Wang (1996), just to name a few. In all these works some form of actual
contact is used in the modelling of the interfacial heat transfer process. A
totally different approach was used to deal with the thermal contact aspect
of the problem based on the following considerations.
First, it is assumed that the outer surface of any wrap is at an infinitesimal
distance from the inner surface of the next outer wrap ( zero distance in the
computations ).
Second, the surfaces facing each other are assumed to exchange heat
according to a film coefficient of heat transfer which is made consistent with
the thermal contact conductance. In effect, the contacting surfaces are
assumed to exchange heat according to a boundary condition of the form:

(15)
where h
tccf
is defined as the thermal contact conductance consistent film
coefficient T, is the heat emmiting surface temperature, and T

is the heat
receiving surface temperature. The form of Eq.(15) is completely analogous
to the form in Eq.(2), and so the complex thermal contact problem has been
reduced to a simple boundary condition. Specific values of n
tccf
are obtained
from published results for TCC values, see for instance (Barzelay et al.,
1955). It should be noted that the proposed approach is at least
macroscopicaly consistent with the heat transfer process at contact.

Numerical Results and Discussion
A double precision FORTRAN code FETAHBRF.FOR ( finite element thermal
analysis hot bar rougher to finisher ) was developed, tested and run off-line
in a VAX 4000/200. Hollander (1967) reports, from experimental
measurements, that a 0.027 m thick carbon steel bar exposed to the
environment loses temperature at an average rate of 2.256 K/s in the
range of 1393.0 K-1203.0 K to be compared with an everage rate of 2.289
K/s for the same range using the present approach. For the coiled portion
of a 0.0254 m thick bar, Stelco reports an average loss of temperature of
0.0556 K/s to be compared with 0.0544 K/s using the present approach.
The particular speed schedule of the bar used in the computations illustrated
here is shown in Fig. 2. The material properties used in the calculations
correspond to the Rimming 0.06% carbon steel and their dependence on
temperature is shown in Table 1 below.

Table 1 Thermal properties of the Rimming 0.06% carbon steel.


These thermal properties were used in the code in the form of minimum
squares fitted polynomials. Figure 3 shows the calculated evolution of
temperature for a 0.0254 m thick 85.34 m long bar, in three groups of three
curves each, corresponding to nine nodal points, based on the initial
temperature distribution shown in Fig.4. Although the actual computations
required 268 time steps Fig. 3 shows 34 time points only, for clarity.


Fig. 3 Temperature evolution at nine bar selected points based on the off-line
solution.


Fig. 4 Initial linear distribution of temperature from head to tail of the bar.

The upper set corresponds to three points located in the upper surface,
middle plane and lower surface respectively at a distance of 0.305 m of the,
initially, head end of the bar. The middle set corresponds to three points
similarly located through the thickness as the ones just mentioned except
that they are located in the center, lengthwise, of the bar. The lower set
corresponds to three points also similarly located as the ones already
mentioned except that they belong to the , initially, tail end of the bar, and
at 0.305 m of the end.
Note that as the bar is coiled and uncoiled, what was originally the head end
of the bar becomes the tail end, and viceversa. The value of
for the contact conductance was used from (Barzelay et
al., 1955). This value corresponds to a surface roughness of 2.54 m at an
interface pressure of 5.2 atm. and 477.0 K.
Each set of three curves exhibits four sectors indicated in Fig. 3.
1. The typical initial exponential temperature loss for the uncoiled parts.
2. A short transition sector corresponding to the process of "temperature
soaking" through the thickness of the bar. This sector coincides with actual
coiling of a given sector of the bar.
3. A third sector where the temperature within the thickness of the wrapped
bar is practically uniform, and temperature loss is reduced to an exponential
curve with large relaxation time.
4. The last sector is similar to the first one in that there is full exposure to
heat loss to the environment and corresponds to uncoiled parts of the bar.
Note that the length of the sectors depends on the position of the points
along the bar. For instance, points at the head end (originally) of the bar
remain coiled longer than any other set of points on the bar, since they are
coiled first and uncoiled last. As a result sector 3 for these points (upper set
of curves in the figure) is longer than it is for any other set of points in the
bar.

On Line Fast Temperature Prediction System OFTPS
Since the numerical solution, in the hot mill process controlling computers,
takes more time than the physical process itself it was necessary to develop
an on-line fast temperature procedure which could be used during the
process itself. The OFTPS as described in this work represents such a device.
The OFTPS is based on the off-line solution of the described model for 5
different thickness (0.0125 m, 0.01875 m, 0.025 m, 0.03125 m and 0.037
m) covering the range of most used bar thicknesses at rougher exit, and it
predicts the temperature at the nine points described above. For this
purpose the curves in Fig. 3 are divided, as already explained in the previous
section, in four identifyable sectors, for each thickness. For each sector,
corresponding to each curve, and for each thickness a least squares
approximating polynomial giving the temperature as a function of time was
developed in the form

(16)
A total of 180 polynomials were generated and chosen so that the least
squares norm is minimized. For some particular sectors, lower degree
polynomials than indicated in Eq.(16) were used, since due to the small
variation of the temperature in these sectors higher degree polynomials
were unnecesary, sector three for the upper set of three curves in Fig. 3, for
example.
The estimated temperature T(x
j
,t) for point x
j
and time t from a given initial
temperature T in (determined through pyrometers in the mill ) is obtained
by adding to the initial temperature the sum of temperature changes A T
i

calculated from the appropriate polynomials, in the following form:

(17)
Each of the four temperature changes correspond to each of the four sectors
in Fig. 4.
The OFTPS system is based on using expression (17) in connection with the
following steps.
1. Given an initial temperature T in for a given point in the bar (actually
determined through a pyrometer appropriately located in the mill), an initial
fictitious time, t in, using the appropriate polynomial ( form in Eq.16 above)
for sector 1 is calculated through a standard Newton-Raphson procedure.
This is illustrated in Fig. 5, where the first sector of the head bottom
temperature curve from Fig. 3 is reproduced.


Fig. 5 Illustration of the procedure to calculate the initial fictitious time
and final temperature for sector 1, for a point on the bottom surface
at the head end of the bar.

2. A final time for the first sector, t sf, is calculated on the basis of the
elapsed time due to the operational speed schedule of the coilbox, Fig. 2.
3. Corresponding to this final time a final temperature for the sector, T sf, is
computed using Eq.(16) again, see Fig. 5.
4. The change of temperature corresponding to the first sector, as an
ilustration, is then simply

(18)
The other three temperature changes calculations in expresion (17) above,
are performed in a totally similar fashion, keeping in mind that the final time
and final temperature of a given sector calculation are the initial time and
the initial temperature of the next sector calculation.
For thicknesses other than the five specified above linear interpolation
among the appropriate polynomials is used.
A sample of the polynomial coeffcients and expressions determined and
incorporated in the OFTPS are given below for 0.025 m thick bars:
For the curve corresponding to a point in the bottom surface of the bar,
head end, in sector 1

(19)
For the curve corresponding to a point in the middle plane of the bar, head
end, in sector 3

(20)
Clearly, the proposed temperature prediction system is independent of the
initial fictitious time tin.
The 180 polynomial expressions of the type indicated in Eq.(16), and
illustrated in Eqs. (19) and (20) have been programmed into hot mill
controlling software. This software uses on-line evaluation of these
polynomial expressions to predict bar temperature at the entry of the
finishing stads in order to contribute to make finishing stands operating
parameter presetting (part of the process operation control) prior to rolling
the oncomming bar.
The OFTPS is operational in hot mills instalations.

Conclusions
A novel and efficient temperature prediction mathematical model and the
corresponding finite element solution is presented for manufacturing
processes requiring coiling. The definition of a film coefficient of heat
transfer consistent with the TCC to treat the complex contact problem
results in a particularly efficient computational scheme since the need for
remeshing and node renumbering at each computational coiling time step is
eliminated. This novel definition also provides the added advantage of
producing the minimum possible bandwith of the resulting equations with
the clear advantage of minimizing CPU time. Herein lies the computational
advantage of the present approach, in this particular regard, over previous
ones which, typically, treat the contact problem in more traditional fashion.
The value of was used for lack of specific experimental
values of the TCC pertaining our particular application. The solution strategy
would not be affected by the particular values of the TCC used, only the
length of sector 2 in Fig. 3 would be modified. Indeed, sector 2 would be
longer for smaller values of the TCC (diminished heat transfer between
contacting surfaces), and shorter for larger values of the TCC ( enhanced
heat transfer between contacting surfaces).
An on-line two-dimensional fast temperature prediction system based on the
model and the solution is presented as well.
We conclude by noting that a three-dimensional solution for the type of
coiling devices described in this work can be found in (Ayala and Troyani,
1998), and by reporting that different numerically efficient strategies are
being examined at present to extend the existing two-dimensional OFTPS to
a three-dimensional version.

References
Ayala O., Troyani N., 1998, "Extensin a Tres Dimensiones de la Simulacin
Numrica del Coilbox por Elementos Finitos", Proc. IV Congreso
Internacional de Mtodos Numricos en Ingeniera y Ciencias Aplicadas,
Ciudad Guayana, Venezuela, pp TC28-TC36. [ Links ]
Barzelay, M. E.,Tong, K. N., Holloway G. F., 1955, NACA, Tech. Note 3295.
[ Links ]
Becker, E. B, Carey, G. F.,and Oden J. T., 1981, "Finite Elements: An
Introduction", Chap. 5, Prentice Hall. [ Links ]
Hollander, F., 1967, "A Model to Calculate the Complete Temperature
Distribution in Steel During Hot Rolling", AISE Year Book , pp 46-78.
[ Links ]
Nakajima K., 1995, "Thermal Contact Resistance Between Balls and Rings of
Bearings under Axial, Radial and Combined Loads", Journal of
Thermophysiscs and Heat Transfer, Vol. 9, N. 9, pp 88-95. [ Links ]
Ozisik, M. N.,1993, "Heat Conduction", Chap. 1, 2
nd
Ed., Wiley.
[ Links ]
Smith, W., 1981 The Coilbox: "A New Approach to Hot Strip Rolling", AISE
Year Book , pp 432-436. [ Links ]
Sridhar, M. R.,Yovanovich, M. M., 1996, "Elastoplastic Contact Conductance
Model for Isotropic Conforming Rough Surfaces and Comparison with
Experiments", Journal of Heat Transfer-Transactions of the ASME, Vol. 118,
pp 3-9. [ Links ]
Troyani, N., 1996, "Nonlinear Geometrically Adaptive Finite Element Model of
the Coilbox", Numerical Heat Transfer, Part A, pp 849-858. [ Links ]
Tseng, A. A., Wang S. R., 1996, Effects of Interface Resistance on Heat
Transfer in Steel Cold-Rolling, Steel Research, Vol. 67, pp 44-51.
[ Links ]


Manuscript received: October 1998; Technical Editor: Angela Ourvio
Nieckele

ABCM
Av. Rio Branco, 124 - 14. Andar
20040-001 Rio de Janeiro RJ - Brazil
Tel. : (55 21) 2221-0438
Fax.: (55 21) 2509-7128

[email protected]
Heat losses by water cooling
The cooling effect of the high-pressure jets (100-150 kg/cm
2
) for scale removal jets is by convection and
the relation q = (Ts-Tw) is valid. It has been found that varies widely over the width and length of the
contact area and has also to be related to the geometry of the nozzle. So other formulations have been
proposed by various researchers[276].
For some mill, laminar jets are in use in the cooling banks. The quantity of heat which is removed from the
steel by a laminar jet has needs to be determined.