CFD analysis of Tungsten Furnace

TUNGSTEN FURNACE : AN OVERVIEW

The tungsten vacuum furnace is an advanced and adaptable thermo vacuum equipment that has transformed numerous sectors, ranging from aerospace and defense to metalworking and research. Tungsten vacuum furnaces are specially engineered to generate a controlled environment devoid of impurities, with vacuum levels reaching up to 10 -5 mbar and temperatures as high as 3000 degrees Celsius. Tungsten, a metal of strategic significance, possesses several remarkable properties. It exhibits an exceptionally high melting point of 3410°C, a density of 19.26 g/cc, and exceptional mechanical strength at elevated temperatures. Additionally, tungsten demonstrates superior thermal stability, excellent shielding capabilities against gamma radiation, and commendable electrical and thermal conductivity. The tungsten vacuum furnace finds utility in diverse sectors including aerospace and defense, metalworking, research and development, and more. Its adaptability enables accurate temperature control, controlled atmospheres, and efficient heating and cooling processes. Consequently, it proves to be an invaluable asset in applications such as heat treatment, brazing, melting, and annealing. The proposed tungsten furnace considered in this project is for Bhabha Atomic Research Centre, Mumbai, India, intended for various metallurgical and research applications, developed by Hind High Vacuum (HHV) Group, a leading vacuum technology company based in Bangalore, India.

OUR ESTEEMED CLIENT

Our valued client, Hind High Vacuum (HHV) Group, is a leading thin film and vacuum technology group in India. With nearly six decades of experience, HHV specializes in designing and manufacturing high vacuum equipment for both research and industrial purposes. Currently, HHV is working on the development of a Tungsten vacuum furnace for the Bhabha Atomic Research Centre, catering to various metallurgical applications. To ensure the success of this project, HHV has sought the expertise of Niharika Computational Engineering Solutions Pvt Ltd (NCES). NCES will provide professional consultancy services in the field of theoretical heat transfer calculations and Computational Fluid Dynamics (CFD) analysis. This collaboration aims to evaluate the thermal performance of the proposed tungsten furnace, ensuring its efficiency and effectiveness. By leveraging NCES's knowledge and experience in heat transfer calculations and CFD analysis, HHV aims to optimize the design and functionality of the tungsten furnace. This partnership highlights HHV's commitment to delivering high-quality and innovative solutions to its clients in the field of vacuum technology.

THEORETICAL HEAT TRANSFER CALCULATIONS

Thermal hand calculations are of utmost importance in enhancing the design and functionality of thermo vacuum systems. These calculations enable engineers to gain a deeper comprehension and analyze the heat transfer mechanisms within the thermo vacuum system, resulting in enhanced efficiency. Through precise predictions of heat transfer rates, temperature distributions, and thermal gradients, engineers can optimize the thermal chamber, insulation, and heating element configuration to achieve maximum efficiency.

COMPUTATIONAL FLUID DYNAMICS (CFD) ANALYSIS

Computational Fluid Dynamics (CFD) is a computational method employed to simulate and examine the behavior of fluid flow and heat transfer phenomena. Through the division of the computational domain into smaller control volumes, CFD computes and solves the governing equations for fluid flow and heat transfer, taking into account different boundary conditions and physical properties. This enables engineers to anticipate fluid flow patterns, temperature distributions, and pressure drops within intricate systems, eliminating the necessity for costly and time-consuming physical prototypes. Additionally, CFD analysis provides the means to visualize and comprehend fluid flow behavior, facilitating the identification of potential design flaws and optimization prospects.

CFD MESH

The CFD mesh for the tungsten furnace comprises 8 million tetrahedral elements, adhering to the mesh quality index specified by industry standards. The mesh is finely resolved in areas with high thermal gradients.

CFD MODELLING

The physics is modeled as 3D, steady state. Radiation is modeled with surface-to-surface (S2S) radiation enclosure model. Material properties and boundary conditions are applied accordingly, taking into account constant interaction with both the HHV Engineering team and the Engineering team of vendors who provided sub-systems to HHV.

The primary focus of the study revolves around analyzing the Temperature field, temperature gradient, radiative heat fluxes on different surfaces, and a comprehensive heat balance sheet that quantifies the flow of heat energy throughout the entire system.