One Dimensional Models for Conduction Heat Transfer

in Manufacturing Processes

P M V Subbarao
Professor
Mechanical Engineering Department
I I T Delhi

Simplified Models for Complex Heat Transfer due

to micro-molecular Movements!!!
 Steady-State One-Dimensional Conduction
• For conduction through a large wall
the heat equation reduces to one
dimensional Equation in Cartesian
system .
• Assume a homogeneous medium
with invariant thermal conductivity (
k = constant) :

T T 2
C p  k 2  g ( x, t )
t x
One dimensional Transient conduction with heat generation.

T  C1 x  C2
Heat Transfer in Metal Cutting

 d 2T d 2T d 2T 
k  2  2  2   0
 dx dy dz 
 Axi-symmetric Conduction Models for Manufacturing
Processes

T    T  1   T    T 
C p    kr  2 k   k   g ( r ,  , z , t )
t  r  r  r     z  z 

No changes in T along  and z directions:

T    T 
C p    kr   g (r )
t  r  r 
Steady state with no heat generation :
   T     T 
k r   0 k   kA   0
 r  r   r  r 
Axi-Symmetric Steady Conduction in Radial Systems

 dT 
d kA 
 dr   0
dr
Homogeneous and constant property material
 dT 
d A
 dr   0
dr
At any radial location the surface are for heat conduction in a solid
cylinder is:

Acylinder  2rl

At any radial location the surface are for heat conduction in a solid
sphere is:

Asphere  4r 2
The GDE for cylinder:  dT 
d r
 dr   0
dr

 dT 
d r 2
 dr   0
The GDE for sphere:
dr
General Solution for Cylinder:

T r   C1 ln r   C2
 dT 
d r
 dr   0 
dr

General Solution for Sphere:

T r   C2 
C1
r
 Boundary Conditions

T r   C1 ln r   C2 T r   C2 
C1
r
• No solution exists when r = 0.
• Totally solid cylinder or Sphere have no physical
relevance!
• Inner wall at finite radius is essential for steady state
conduction with no heat generation.
 UNSTEADY-STATE HEAT CONDUCTION

Applications where rate/duration of heating/cooling

is a Design Parameter……
Welding Process : How to decide the Rate of
Welding?
 Injection Molding Process

They need you to help them to the time required for a part in a mold
to cool to an acceptable temperature for removal.
 Resin Transfer Molding Process

(1) Insert fiber preform

(2) Close mold
(3) Inject mixed
resin/catalyst
(4) Part solidifies via
reaction
(5) Open mold
(6) Remove part
The cycle time for step (4) is approximately the same 25 minutes
for parts of all sizes made by AeroForm.
All other molding operations (1), (2), (3), (5) and (6) take a total
of 5 minutes.
Selective LASER Sintering
 General Conduction Equation
• The general form of these equations in multi-dimensions for
homogeneous material is:
T g ( x, t )
  T 
2

t C p
For Cartesian Geometry:

T   T  T  T  g ( x, y, z : t )
2 2 2
 2  2  2  
t  x y z  C p
Cooling/Quenching of Hot Processed Products
 Transient-conduction
• If we have a ball with initial temperature
of T0 and it is left in fluid at Te.
• Heat is transferred by convection at the
surface.
• As the surface temperature decreases,
heat is transferred from the center of the
ball to the surface, then to the fluid.

•Temperature will vary with location within

a system and with time.
•Temperature and rate heat transfer variation
of a system are dependent on its internal
resistance and surface resistance.
 First Law Analysis of Cooling /Quenching of Hot
Object s
Rate of Change in energy of hot object= Rate of Heat transfer

Rate of Heat Transfer = Rate of Convection by fluid =

Rate of Conduction transfer in the metal ball

dU
Rate of change in enegy :
dt
d  cTdV
dU
 V
dt dt
 
R
d  c 4r 2 T (r , t )dr
For spherical objects dU
 0
dt dt
 T0 T

Rcond Rconv

Total thermal resistance of the system: Rtot

T0 T

At any instant:

 
R
d  c 4r 2 T (r , t )dr
dT r , t 
0
 kAcond  hAconv T ( R, t )  Te 
dt dr r  R
•A Biot number is defined as:

Covection heat removal from Surface of Object

Bi 
Heat Lost by Object by Conduction within

hAconv T ( R, t )  T 
Bi 
dT r , t 
kAcond
dr r  R

hAconv T0  T  hAconv hLcharacteristic

Bi   
T0  T  kAcond k solid
kAcond  
 R  Lcharacteristic
Relationship between the Biot number and the temperature
profile.
 System with negligible internal resistance

For this case Bi  1.0.and the temperature profile within the body is
quite uniform.
The rate of change in internal energy of the
body is equal to the rate of heat taken away
from the surface by convection:

d  cT (t )dV

V
 hAconv T (t )  T 
dt

d cVT 
 hAconv T (t )  T 
dt
  hAconv T (t )  T 
dT
cV
dt

Rearranging:

dT hAconv
 dt
T (t )  T  cV

Integrating to any time interval:

T 
dT hAconv
T T (t )  T    cV 0 dt
0
  T  T  hA
ln   
T0  T  cV

hA
T  T 
cV

e
T0  T
cV
Define, Thermal Time Constant c 
hA

T  T 
c
e
T0  T
 T  T
T 
*

T0  T

t thA
t  
*

 c cV
 1 
Thermal Time Constant  c   CV 
 hA 
 c  RthCth
The total energy transferred during time t
t
Q   hAT  T dt
t
Q   Q convdt
0 0


t 
t

Q  hA   T0  T e  c dt
0
 

t 
t

Q  hAT0  T  e c
dt
0
 Hot Rolling of Steel Sheets

 1
hLcharacteristic
Bi 
k solid