Simulation and Experimental Methodology for Virtual Prototyping of Annealed Industrial Coils

Abstract

The finite element three-dimensional transient model of the annealing process, including conductive and convective heat transfer in an aluminum (Al) coil was developed, implemented, and validated. It combines winding force dependent effective radial thermal conductivity model and the novel convective heat transfer modeling methodology. Experimental validation of the finite element model was performed for two industrial coils having different dimensions, strip thickness and crowning depth. The general agreement between the predicted and measured temperatures for most of the probes was better than 10% at the target material temperature. A series of measurements were configured and performed to supply both the input and validation data for the simulations. The effect of the additional wetted area on the convective heat transfer at the coil base was quantified. The guidelines on the virtual prototyping of the Al coil annealing process were provided, which can be of interest for the process designers.