Modeling methods of a rotary hearth forging furnace
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A series of single-physics heat and mass transfer models of a rotary hearth forging furnace are studied for design, selection, and implementation into a multi-physics full system model with a mind towards accuracy and computational efficiency. The transfer modes studied are fluid mass flow, mass-coupled enthalpy transfer, thermal conduction, thermal convection, radiative heat transfer, and steel oxidation. Each mode has one or more associated submodels which are compared for accuracy and efficiency against baseline high fidelity models. A novel model of zonal radiative heat transfer calculations is presented and compared to the radiative heat transfer of a full furnace geometry solved by finite element analysis. A full system model was developed by combining the optimal single-physics submodels according to criteria that favored both speed and accuracy. This system model was then put through a parameter sensitivity analysis for the purpose of identifying which uncontrollable parameters require further accuracy and which controllable parameters are best modified for temperature set point optimization. The system model was also put through an optimization function which determined locally optimal input parameters within a selected parameter space. These optima were compared for the purpose of maximizing furnace efficiency.