SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017
Finite Difference Analysis of Induction Furnace
Wall for Magnesia Ramming Mass
Nirajkumar C Mehta1, Dr. Dipesh D Shukla2
1
Ph. D. Student, Rai University, Ahmedabad, India
2
Director, Amity University, Jaipur, India
Abstract
Furnaces are useful for melting different
materials for casting process. In this research paper,
we had done advanced heat transfer analysis of
induction furnace wall made of magnesia ramming
mass using explicit finite difference method. We have
divided actual geometry of furnace refractory wall into
14 elements and 24 nodes. We have derived explicit
finite difference equations for all 24 nodes. We have
calculated temperature distribution and thermal stress
distribution for all different nodes with respect to time.
We have plotted graphs for maximum temperature v/s
time and maximum stress v/s time. We found that results
indicate the effect of thermal fatigue in the induction
furnace wall for magnesia ramming mass. The analysis
is very helpful in understanding how thermal fatigue
failure of refractory wall happens.
Keywords: Advanced heat transfer analysis,
Temperature distribution, Stress distribution, explicit
finite difference method, Magnesia ramming mass
I. INRODUCTION
Furnace is a term used to identify a closed
space here heat is applied to a body in order to raise its
temperature. The source of heat may be fuel or
electricity. Commonly, metals and alloys and
sometimes non-metals are heated in furnaces. The
purpose of heating defines the temperature of heating
and heating rate. Increase in temperature softens the
metals. They become amenable to deformation. This
softening occurs with or without a change in the
metallic structure. Heating to lower temperatures
(below the critical temperature) of the metal softens it
by relieving the internal stresses. On the other hand,
metals heated to temperatures above the critical
temperatures leads to changes in crystal structures and
recrystallization like annealing. Some metals and alloys
are melted, ceramic products vitrified, coals coked,
metals like zinc are vaporized and many other processes
are performed in Furnaces. [17]
Induction furnaces are widely used in the iron
industry for the casting of the different grades of cast
iron products. Refractory wall of induction melting
ISSN: 2395 - 0250 www.internationaljournalssrg.org
furnace is a key component which is used as insulation
layer. It is made of ramming mass like magnesia, silica,
alumina etc. The refractory wall is directly influenced
by the thermal cycling of the high temperature molten
iron in the furnace. Thermal fatigue failure is easy to
happen for it because of the larger phase transformation
thermal stresses and it has a shorter life. This can cause
serious production accidents. Therefore, the service life
problem of the refractory wall has always been a focus
of attention in the application of this to the industry.
[19]
The research on the distribution rule of
temperature and thermal stress field and on the fatigue
life assessment method for the refractory wall will not
only lay foundation for the study on the thermal fatigue
of this kind of parts under thermal shock condition of
low cycle and high phase transition stresses but also
offers effective control for thermal fatigue failure.
A comprehensive literature review on
computational investigation on different kinds of
furnaces is done to study research trends. [1] A review
is done on applications of different numerical methods
in heat transfer with its applications. [2] Thermal
fatigue analysis of induction melting furnace wall is
done for silica ramming mass. [3] A review is done for
research on induction heating. [4] A review is done for
metal forming analysis using different numerical
methods. [5] Transient heat transfer analysis of
induction furnace is done by using finite element
analysis. [6] Thermal fatigue analysis of induction
furnace wall is done for alumina ramming mass. [7]
Thermal analysis of hot wall condenser is done
for domestic refrigerator using numerical method for
temperature distribution. [8] Optimization of wall
thickness is done for minimum heat loss for induction
furnace by finite element analysis. [9] A review is done
on numerical analysis of furnace. [10] Thermal fatigue
analysis of induction furnace wall is done for zirconia.
[11] Comparison of finite difference method and finite
element method is done for 2 D transient heat transfer
problem. [12] Thermal fatigue analysis of induction
furnace wall is done for magnesia ramming mass. [13]
Advanced mathematical modeling of heat transfer is
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 SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017

done for induction furnace wall of zirconia. [14]

Advanced heat transfer analysis is done for alumina
based refractory wall of induction furnace. [15]
Prediction of Life Cycle is done for Induction Furnace
Wall for Silica Ramming Mass. [16]

Here, Explicit Finite Difference Method is

used to find out temperature and thermal stress
variation with respect to time.

II. DEVELOPMENT OF ADVANCED HEAT

TRANSFER MODEL

We have divided Induction Furnace Wall into

a Nodal Network as shown in Fig. 1. It is divided into
24 nodes. We have derived Explicit Finite Difference
Equations for all nodes as per the boundary conditions
applied to it. The furnace wall is having thermal
conduction heat transfer between different nodes. It is
having atmospheric heat convection ha applied from
top side of the furnace wall which is open to Fig. 1. Nodal Network for Finite Difference Method
atmosphere. It is having heat convection from molten
metal from inside which is hi. It is having heat Node 1:
convection ho from cooling water which is circulating ∆𝑥 ∆𝑦 ∆𝑦 𝑇2𝑖 − 𝑇1𝑖
outside the furnace wall. [18] ℎ𝑎 (𝑇∞ − 𝑇1𝑖 )+ ℎ𝑜 (𝑇∞ − 𝑇1𝑖 ) + k +
2 2 2 ∆𝑥
∆𝑥 𝑇4𝑖 − 𝑇1𝑖 ∆𝑥 ∆𝑦 𝑇1𝑖+1 −𝑇1𝑖
To solve this advanced heat transfer problem k =𝜌 ∁
2 ∆𝑦 2 2 ∆𝑡
∆𝑥 ∆𝑦
of induction melting furnace wall which is made from 𝑇1𝑖+1 = ((ℎ𝑎 (𝑇∞ − 𝑇1𝑖 )+ ℎ𝑜 (𝑇∞ − 𝑇1𝑖 ) +
2 2
Magnesia Ramming Mass, the following initial and ∆𝑦 𝑇2𝑖 − 𝑇1𝑖 ∆𝑥 𝑇4𝑖 − 𝑇1𝑖 4∆𝑡
boundary conditions, material properties and basic k +k ) )+ 𝑇1𝑖
2 ∆𝑥 2 ∆𝑦 𝜌∁∆𝑥∆𝑦
assumptions are made: T[1][i+1] = (((0.5*ha*x*(To-T[1][i])) +(ho*y*(Ta-
T[1][i])/2)+(0.5*k*y*(T[2][i]-
 Refractory Materials for induction furnace T[1][i])/x)+(0.5*k*x*(T[4][i]-T[1][i])/y)
wall meets the basic assumptions in the )*((4*t)/(r*c*x*y))) +T[1][i];
science of mechanics.
 Environmental Temperature is homogeneous
Node 2:
at 27° C. ∆𝑦 𝑇1𝑖 − 𝑇2𝑖 ∆𝑦 𝑇3𝑖 − 𝑇2𝑖 𝑇5𝑖 − 𝑇2𝑖
 Ignore the influence of heat radiation. ℎ𝑎∆𝑥(𝑇∞ − 𝑇2𝑖 )+ k +k + k∆𝑥 =
2 ∆𝑥 2 ∆𝑥 ∆𝑦
 Ignore the effect of gravity field. ∆𝑦 𝑇2𝑖+1 −𝑇2𝑖
 The surface of induction melting furnace wall 𝜌∆𝑥 ∁
2 ∆𝑡
is clean. ∆𝑦 𝑇1𝑖 − 𝑇2𝑖 ∆𝑦 𝑇3𝑖 − 𝑇2𝑖
𝑇2𝑖+1 = ((ℎ𝑎∆𝑥(𝑇∞ − 𝑇2𝑖 )+ k +k +
 The initial temperature of the induction 2 ∆𝑥 2 ∆𝑥
𝑇5𝑖 − 𝑇2𝑖 2∆𝑡
melting furnace is set 27° C and it is k∆𝑥 ) ) + 𝑇2𝑖
∆𝑦 𝜌∁∆𝑥∆𝑦
agreement with the ambient temperature
T[2][i+1] = (((ha*x*(To-
during solving the problem.
T[2][i]))+(0.5*k*y*(T[1][i]-
 Heat convections are considered constant for
this analysis. T[2][i])/x)+(0.5*k*y*(T[3][i]-T[2][i])/x)
 Scarp material input inside furnace is +(0.5*k*x*(T[5][i]-T[2][i])/y))*((2*t)/(r*c*x*y)))
considered uniform for our analysis. +T[2][i];

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 SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017

Node 3: Node 7:
∆𝑥 ∆𝑦 ∆𝑦 𝑇2𝑖 − 𝑇3𝑖 𝑇8𝑖 − 𝑇7𝑖 ∆𝑥 𝑇4𝑖 − 𝑇7𝑖 𝑖 − 𝑇𝑖
∆𝑥 𝑇10
ℎ𝑎 (𝑇∞ − 𝑇3𝑖 )+ ℎ𝑖 (𝑇ℎ − 𝑇3𝑖 ) +k + ℎ𝑜∆𝑦(𝑇∞ − 𝑇7𝑖 ) + k∆𝑦 +k +k 7
=
2 2 2 ∆𝑥 ∆𝑥 2 ∆𝑦 2 ∆𝑦
∆𝑥 𝑇6𝑖 − 𝑇3𝑖 ∆𝑥 ∆𝑦 𝑇3𝑖+1 −𝑇3𝑖 ∆𝑥 𝑇7𝑖+7 −𝑇7𝑖
k =𝜌 ∁ 𝜌 ∆𝑦∁
2 ∆𝑦 2 2 ∆𝑡 2 ∆𝑡
𝑖+1 ∆𝑥 ∆𝑦 𝑇8𝑖 − 𝑇7𝑖 ∆𝑥 𝑇4𝑖 − 𝑇7𝑖
𝑇3 = (( ℎ𝑎 (𝑇∞ − 𝑇3𝑖 )+ ℎ𝑖 (𝑇ℎ − 𝑇3𝑖 ) + 𝑇7𝑖+7 = (( ℎ𝑜∆𝑦(𝑇∞ − 𝑇7𝑖 ) + k∆𝑦 +k +
2 2 ∆𝑥 2 ∆𝑦
∆𝑦 𝑇2𝑖 − 𝑇3𝑖 ∆𝑥 𝑇6𝑖 − 𝑇3𝑖 4∆𝑡 𝑖 − 𝑇𝑖
k +k ) )+ 𝑇3𝑖 k
∆𝑥 𝑇10 7
)
2∆𝑡
) + 𝑇7𝑖
2 ∆𝑥 2 ∆𝑦 𝜌∁∆𝑥∆𝑦
2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[3][i+1] = (((ha*x*(To-T[3][i])*0.5) +( hi*y*(Th- T[7][i+1] = (((ho*y*(Ta-T[7][i])) + (k*y*(T[8][i]-
T[3][i])*0.5 ) +(0.5*k*y*(T[2][i]- T[7][i])/x)+(0.5*k*x*(T[4][i]-T[7][i])/y) +
T[3][i])/x)+(0.5*k*x*(T[6][i]-T[3][i])/y)) (0.5*k*x*(T[10][i]-T[7][i])/y)) *((2*t)/(r*c*x*y)))
*((4*t)/(r*c*x*y))) +T[3][i]; +T[7][i];
Node 4: Node 8:
𝑇5𝑖 − 𝑇4𝑖 ∆𝑥 𝑇1𝑖 − 𝑇4𝑖 ∆𝑥 𝑇7𝑖 − 𝑇4𝑖
ℎ𝑜∆𝑦(𝑇∞ − 𝑇4𝑖 ) + k∆𝑦 +k +k = k∆𝑦
𝑇7𝑖 − 𝑇8𝑖
+ k∆𝑦
𝑇9𝑖 − 𝑇8𝑖
+ k∆𝑥
𝑇5𝑖 − 𝑇8𝑖
+ k∆𝑥
𝑖 − 𝑇𝑖
𝑇11 8
=
∆𝑥 2 ∆𝑦 2 ∆𝑦
∆𝑥 ∆𝑥 ∆𝑦 ∆𝑦
∆𝑥 𝑇4𝑖+4 −𝑇4𝑖
𝜌 ∆𝑦∁ 𝑇8𝑖+1 −𝑇8𝑖
2 ∆𝑡 𝜌∆𝑥∆𝑦∁
∆𝑡
𝑇7𝑖 − 𝑇8𝑖 𝑇9𝑖 − 𝑇8𝑖 𝑇5𝑖 − 𝑇8𝑖
𝑇5𝑖 − 𝑇4𝑖 ∆𝑥 𝑇1𝑖 − 𝑇4𝑖 𝑇8𝑖+1 = (( k∆𝑦 + k∆𝑦 + k∆𝑥 +
𝑇4𝑖+4 = ((ℎ𝑜∆𝑦(𝑇∞ − 𝑇4𝑖 ) + k∆𝑦 +k + ∆𝑥 ∆𝑥 ∆𝑦
∆𝑥 2 ∆𝑦 𝑖 − 𝑇𝑖
𝑇11 ∆𝑡
∆𝑥 𝑇7𝑖 − 𝑇4𝑖 2∆𝑡 k∆𝑥 8
) ) + 𝑇8𝑖
k ) ) + 𝑇4𝑖 ∆𝑦 𝜌∁∆𝑥∆𝑦
2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[8][i+1] = (((k*y*(T[7][i]-T[8][i])/x)+(
T[4][i+1] = ((( ho*y*(Ta-T[4][i])) +(k*y*(T[5][i]- k*y*(T[9][i]-T[8][i])/x ) +(k*x*(T[5][i]-T[8][i])/y)
T[4][i])/x)+(0.5*k*x*(T[1][i]-T[4][i])/y) + + (k*x*(T[11][i]-T[8][i])/y)) *((t)/(r*c*x*y)))
(0.5*k*x*(T[7][i]-T[4][i])/y)) *((2*t)/(r*c*x*y))) +T[8][i];
+T[4][i];

Node 5: Node 9:
𝑇4𝑖 − 𝑇5𝑖 𝑇6𝑖 − 𝑇5𝑖 𝑇2𝑖 − 𝑇5𝑖 𝑇8𝑖 − 𝑇5𝑖
k∆𝑦 + k∆𝑦 + k∆𝑥 + k∆𝑥 = 𝑇8𝑖 − 𝑇9𝑖 ∆𝑥 𝑇6𝑖 − 𝑇9𝑖 𝑖 − 𝑇𝑖
∆𝑥 𝑇12
∆𝑥 ∆𝑥 ∆𝑦 ∆𝑦 ℎ𝑖∆𝑦(𝑇ℎ − 𝑇9𝑖 ) + k∆𝑦 +k +k 9
=
∆𝑥 2 ∆𝑦 2 ∆𝑦
𝑇5𝑖+1 −𝑇5𝑖
𝜌∆𝑥∆𝑦∁ ∆𝑥 𝑇9𝑖+1 −𝑇9𝑖
∆𝑡 𝜌 ∆𝑦∁
2 ∆𝑡
𝑇4𝑖 − 𝑇5𝑖 𝑇6𝑖 − 𝑇5𝑖 𝑇2𝑖 − 𝑇5𝑖
𝑇5𝑖+1 = ((k∆𝑦 + k∆𝑦 + k∆𝑥 + 𝑇8𝑖 − 𝑇9𝑖 ∆𝑥 𝑇6𝑖 − 𝑇9𝑖
∆𝑥 ∆𝑥 ∆𝑦 𝑇9𝑖+1 = ((ℎ𝑖∆𝑦(𝑇ℎ − 𝑇9𝑖 ) + k∆𝑦 +k +
∆𝑥 2 ∆𝑦
𝑇8𝑖 − 𝑇5𝑖 ∆𝑡 𝑖 − 𝑇𝑖
k∆𝑥 ) )+ 𝑇5𝑖 k
∆𝑥 𝑇12 9
)
2∆𝑡
) + 𝑇9𝑖
∆𝑦 𝜌∁∆𝑥∆𝑦
2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[5][i+1] = (((k*y*(T[4][i]- T[9][i+1] = (( (hi*y*(Th-T[9][i]))+(k*y*(T[8][i]-
T[5][i])/x)+(k*y*(T[6][i]-T[5][i])/x) + T[9][i])/x)+ (0.5*k*x*(T[6][i]-T[9][i])/y) +
(k*x*(T[8][i]-T[5][i])/y)) *((t)/(r*c*x*y))) +T[5][i]; (0.5*k*x*(T[12][i]-T[9][i])/y)) *((2*t)/(r*c*x*y)))
+T[9][i];
Node 6:
𝑇2𝑖 − 𝑇6𝑖 ∆𝑥 𝑇3𝑖 − 𝑇6𝑖 ∆𝑥 𝑇9𝑖 − 𝑇6𝑖
ℎ𝑖∆𝑦(𝑇ℎ − 𝑇6𝑖 ) + k∆𝑦 +k +k = Node 10:
∆𝑥 2 ∆𝑦 2 ∆𝑦 𝑖 − 𝑇𝑖
𝑖 𝑇11 10 ∆𝑥 𝑇7𝑖 − 𝑇10
𝑖
∆𝑥 𝑇6𝑖+1 −𝑇6𝑖 ℎ𝑜∆𝑦(𝑇∞ − 𝑇10 ) + k∆𝑦 +k +
𝜌 ∆𝑦∁ ∆𝑥 2 ∆𝑦
2 ∆𝑡 𝑖 − 𝑇𝑖 𝑖+10 −𝑇 𝑖
∆𝑥 𝑇15 ∆𝑥 𝑇10
𝑇2𝑖 − 𝑇6𝑖 ∆𝑥 𝑇3𝑖 − 𝑇6𝑖 k 10
=𝜌 ∆𝑦∁ 10
𝑇6𝑖+1 = (( ℎ𝑖∆𝑦(𝑇ℎ − 𝑇6𝑖 ) + k∆𝑦 +k + 2 ∆𝑦 2 ∆𝑡
∆𝑥 2 ∆𝑦 𝑖 − 𝑇𝑖
𝑇11 ∆𝑥 𝑇7𝑖 − 𝑇10
𝑖
∆𝑥 𝑇9𝑖 − 𝑇6𝑖 2∆𝑡 𝑖+10
𝑇10 = ((ℎ𝑜∆𝑦(𝑇∞ − 𝑖
𝑇10 ) + k∆𝑦 10
+k
k ) ) + 𝑇6𝑖 ∆𝑥 2 ∆𝑦
2 ∆𝑦 𝜌∁∆𝑥∆𝑦 𝑖 − 𝑇𝑖
∆𝑥 𝑇15 10 2∆𝑡 𝑖
+k ) )+ 𝑇10
2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[6][i+1] = (((hi*y*(Th-T[6][i])) + (k*y*(T[2][i]-
T[10][i+1] = (( (ho*y*(Ta-
T[6][i])/x)+(0.5*k*x*(T[3][i]-T[6][i])/y) +
T[10][i]))+(k*y*(T[11][i]-T[10][i])/x)+
(0.5*k*x*(T[9][i]-T[6][i])/y)) *((2*t)/(r*c*x*y)))
(0.5*k*x*(T[7][i]-T[10][i])/y) + (0.5*k*x*(T[15][i]-
+T[6][i];
T[10][i])/y)) *((2*t)/(r*c*x*y))) +T[10][i];

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 SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017

Node 11: (0.5*k*x*(T[19][i]-T[14][i])/y)) *((4*t)/(r*c*x*y)))

𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖 𝑇8𝑖 − 𝑇11
𝑖
k∆𝑦
𝑇10 11
+ k∆𝑦
𝑇12 11
+ k∆𝑥 + +T[14][i];
∆𝑥 ∆𝑥 ∆𝑦
𝑖 − 𝑇𝑖
𝑇16 𝑖+1 −𝑇 𝑖
𝑇11
11 11
k∆𝑥 = 𝜌∆𝑥∆𝑦∁ Node 15:
∆𝑦 ∆𝑡 𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖
𝑖 𝑇16 15 ∆𝑥 𝑇10 15
𝑖+1
𝑖 − 𝑇𝑖
𝑇10 11
𝑖 − 𝑇𝑖
𝑇12 11 𝑇8𝑖 − 𝑇11
𝑖 ℎ𝑜∆𝑦(𝑇∞ − 𝑇15 ) + k∆𝑦 +k +
𝑇11 = (( k∆𝑦 + k∆𝑦 + k∆𝑥 + ∆𝑥 2 ∆𝑦
∆𝑥 ∆𝑥 ∆𝑦 𝑖 − 𝑇𝑖 𝑖+15 −𝑇 𝑖
∆𝑥 𝑇20 15 ∆𝑥 𝑇15 15
𝑖 − 𝑇𝑖
𝑇16 11 ∆𝑡 𝑖 k =𝜌 ∆𝑦∁
k∆𝑥 ) ) + 𝑇11 2 ∆𝑦 2 ∆𝑡
∆𝑦 𝜌∁∆𝑥∆𝑦 𝑖 − 𝑇𝑖
𝑖+15 𝑖 𝑇16 15
T[11][i+1] = (( (k*y*(T[10][i]-T[11][i])/x)+ 𝑇15 = (( ℎ𝑜∆𝑦(𝑇∞ − 𝑇15 ) + k∆𝑦 +
∆𝑥
(k*y*(T[12][i]-T[11][i])/x)+ (k*x*(T[8][i]- 𝑖 − 𝑇𝑖
∆𝑥 𝑇10 15
𝑖 − 𝑇𝑖
∆𝑥 𝑇20 15 2∆𝑡 𝑖
T[11][i])/y) + (k*x*(T[16][i]-T[11][i])/y)) k +k ) ) + 𝑇15
2 ∆𝑦 2 ∆𝑦 𝜌∁∆𝑥∆𝑦
*((t)/(r*c*x*y))) +T[11][i]; T[15][i+1] = (( (ho*y*(Ta-
T[15][i]))+(k*y*(T[16][i]-T[15][i])/x)+
Node 12: (0.5*k*x*(T[10][i]-T[15][i])/y)+( 0.5*k*x*(T[20][i]-
∆𝑥 𝑖 ∆𝑦 𝑖
𝑖 − 𝑇𝑖
𝑇11 12 T[15][i])/y)) *((2*t)/(r*c*x*y))) +T[15][i];
ℎ𝑖 (𝑇ℎ − 𝑇12 ) + ℎ𝑖 (𝑇ℎ − 𝑇12 ) + k∆𝑦 +
2 2 ∆𝑥
𝑖 − 𝑇𝑖
∆𝑦 𝑇13 12 ∆𝑥 𝑇9𝑖 − 𝑇12
𝑖 𝑖 − 𝑇𝑖
𝑇17 12
k +k + k∆𝑥 = Node 16:
2 ∆𝑥 2 ∆𝑦 ∆𝑦 𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖
𝑇15 16 𝑇17 16 𝑇11 16
𝑖+1 −𝑇 𝑖
3∆𝑥∆𝑦 𝑇12 12 k∆𝑦 + k∆𝑦 + k∆𝑥 +
𝜌 ∁ ∆𝑥 ∆𝑥 ∆𝑦
4 ∆𝑡 𝑖 − 𝑇𝑖 𝑖+1 −𝑇 𝑖
∆𝑥 ∆𝑦 𝑇21 16 𝑇16 16
𝑖+1
𝑇12 = (( ℎ𝑖 𝑖
(𝑇ℎ − 𝑇12 ) + ℎ𝑖 𝑖
(𝑇ℎ − 𝑇12 ) + k∆𝑥 = 𝜌∆𝑥∆𝑦∁
2 2 ∆𝑦 ∆𝑡
𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖
𝑖 − 𝑇𝑖
𝑇11 𝑖 − 𝑇𝑖
∆𝑦 𝑇13 ∆𝑥 𝑇9𝑖 − 𝑇12
𝑖
𝑖+1 𝑇15 16 𝑇17 16 𝑇11 16
k∆𝑦 12
+k 12
+k + 𝑇16 = (( k∆𝑦 + k∆𝑦 + k∆𝑥 +
∆𝑥 2 ∆𝑥 2 ∆𝑦 ∆𝑥 ∆𝑥 ∆𝑦
𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖
𝑇21 ∆𝑡
𝑇17 4∆𝑡 𝑖 16 𝑖
k∆𝑥 12
) ) + 𝑇12 k∆𝑥 ) ) + 𝑇16
∆𝑦 3𝜌∁∆𝑥∆𝑦 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[12][i+1] = (( (0.5*hi*x*(Th-T[12][i]))+( T[16][i+1] = (( (k*y*(T[15][i]-T[16][i])/x)+
0.5*hi*y*(Th-T[12][i])) +(k*y*(T[11][i]- (k*y*(T[17][i]-T[16][i])/x )+(k*x*(T[11][i]-
T[12][i])/x)+ (0.5*k*y*(T[13][i]-T[12][i])/x) + T[16][i])/y)+( k*x*(T[21][i]-T[16][i])/y))
(0.5*k*x*(T[9][i]-T[12][i])/y) + (k*x*(T[17][i]- *((t)/(r*c*x*y))) +T[16][i];
T[12][i])/y)) *((4*t)/(3*r*c*x*y))) +T[12][i];
Node 17:
𝑖 − 𝑇𝑖
𝑇16 𝑖 − 𝑇𝑖
𝑇18 𝑖 − 𝑇𝑖
𝑇12
Node 13: k∆𝑦 17
+ k∆𝑦 17
+ k∆𝑥 17
+
𝑖 − 𝑇𝑖
∆𝑦 𝑇12 𝑖 − 𝑇𝑖
∆𝑦 𝑇14 ∆𝑥 ∆𝑥 ∆𝑦
𝑖 13 13
ℎ𝑖∆𝑥(𝑇ℎ − 𝑇13 )+ k +k + 𝑖 − 𝑇𝑖
𝑇22 𝑖+1 −𝑇 𝑖
𝑇17
2 ∆𝑥 2 ∆𝑥 k∆𝑥 17
= 𝜌∆𝑥∆𝑦∁ 17
𝑖 − 𝑇𝑖
𝑇18 ∆𝑦 𝑖+1 −𝑇 𝑖
𝑇13 ∆𝑦 ∆𝑡
13 13
k∆𝑥 = 𝜌∆𝑥 ∁ 𝑖 − 𝑇𝑖
𝑇16 𝑖 − 𝑇𝑖
𝑇18 𝑖 − 𝑇𝑖
𝑇12
∆𝑦 2 ∆𝑡 𝑖+1 17 17 17
𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖 𝑇17 = (( k∆𝑦 + k∆𝑦 + k∆𝑥 +
𝑖+1 𝑖 ∆𝑦 𝑇12 13 ∆𝑦 𝑇14 13 ∆𝑥 ∆𝑥 ∆𝑦
𝑇13 = (( ℎ𝑖∆𝑥(𝑇ℎ − 𝑇13 )+ k +k + 𝑖 − 𝑇𝑖
𝑇22 ∆𝑡
2 ∆𝑥 2 ∆𝑥 17 𝑖
𝑖 − 𝑇𝑖
𝑇18 2∆𝑡
k∆𝑥 ) ) + 𝑇17
13 𝑖 ∆𝑦 𝜌∁∆𝑥∆𝑦
k∆𝑥 ) )+ 𝑇13
∆𝑦 𝜌∁∆𝑥∆𝑦 T[17][i+1] = (( (k*y*(T[16][i]-T[17][i])/x)+
T[13][i+1] = (( (hi*x*(Th- (k*y*(T[18][i]-T[17][i])/x )+(k*x*(T[12][i]-
T[13][i]))+(0.5*k*y*(T[12][i]-T[13][i])/x)+ T[17][i])/y)+( k*x*(T[22][i]-T[17][i])/y))
(0.5*k*y*(T[14][i]-T[13][i])/x)+ (k*x*(T[18][i]- *((t)/(r*c*x*y))) +T[17][i];
T[13][i])/y)) *((2*t)/(r*c*x*y))) +T[13][i];
Node 18:
Node 14: 𝑖 − 𝑇𝑖
𝑇17 𝑖 − 𝑇𝑖
𝑇19 𝑖 − 𝑇𝑖
𝑇13
18 18 18
∆𝑥 ∆𝑦 𝑖 − 𝑇𝑖
∆𝑦 𝑇13
k∆𝑦 + k∆𝑦 + k∆𝑥 +
𝑖 𝑖 14 ∆𝑥 ∆𝑥 ∆𝑦
ℎ𝑖 (𝑇ℎ − 𝑇14 )+ ℎ𝑖 (𝑇ℎ − 𝑇14 )+k + 𝑖 − 𝑇𝑖 𝑖+1 −𝑇 𝑖
2 2 2 ∆𝑥 𝑇23 18 𝑇18 18
𝑖 − 𝑇𝑖
∆𝑥 𝑇19 ∆𝑥 ∆𝑦 𝑖+1 −𝑇 𝑖
𝑇14 k∆𝑥 = 𝜌∆𝑥∆𝑦∁
k 14
=𝜌 ∁ 14 ∆𝑦 ∆𝑡
2 ∆𝑦 2 2 ∆𝑡 𝑖 − 𝑇𝑖
𝑇17 𝑖 − 𝑇𝑖
𝑇19 𝑖 − 𝑇𝑖
𝑇13
𝑖+1 18 18 18
𝑖+1 ∆𝑥 𝑖 ∆𝑦 𝑖 𝑇18 = ((k∆𝑦 + k∆𝑦 + k∆𝑥 +
𝑇14 = (( ℎ𝑖 (𝑇ℎ − 𝑇14 )+ ℎ𝑖 (𝑇ℎ − 𝑇14 )+ ∆𝑥 ∆𝑥 ∆𝑦
2 2 𝑖 − 𝑇𝑖
𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖 𝑇23 18 ∆𝑡 𝑖
k
∆𝑦 𝑇13 14
+k
∆𝑥 𝑇19 14
)
4∆𝑡 𝑖
) + 𝑇14 k∆𝑥 ) ) + 𝑇18
∆𝑦 𝜌∁∆𝑥∆𝑦
2 ∆𝑥 2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[14][i+1] = (( (0.5*hi*x*(Th- T[18][i+1] = (( (k*y*(T[17][i]-T[18][i])/x)+
T[14][i]))+(0.5*hi*y*(Th-T[14][i])) (k*y*(T[19][i]-T[18][i])/x )+(k*x*(T[13][i]-
+(0.5*k*y*(T[13][i]-T[14][i])/x)+ T[18][i])/y)+( k*x*(T[23][i]-T[18][i])/y))
*((t)/(r*c*x*y))) +T[18][i];

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 SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017

𝑖 − 𝑇𝑖
∆𝑦 𝑇22 𝑖 − 𝑇𝑖
∆𝑦 𝑇24
𝑖 23 23
ℎ𝑜∆𝑥(𝑇∞ − 𝑇23 )+ k +k +
Node 19: 2 ∆𝑥 2 ∆𝑥
𝑖 − 𝑇𝑖
𝑇18 𝑖+1 −𝑇 𝑖
∆𝑦 𝑇23
𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖 23 23
𝑖
ℎ𝑖∆𝑦(𝑇ℎ − 𝑇19 ) + k∆𝑦
𝑇18 19
+k
∆𝑥 𝑇14 19
+ k∆𝑥 = 𝜌∆𝑥 ∁
∆𝑦 2 ∆𝑡
∆𝑥 2 ∆𝑦 𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖
𝑖 − 𝑇𝑖 𝑖+1 −𝑇 𝑖 𝑖+1 𝑖 ∆𝑦 𝑇22 23 ∆𝑦 𝑇24 23
k
∆𝑥 𝑇24 19
=𝜌
∆𝑥
∆𝑦∁
𝑇19 19 𝑇23 = ((ℎ𝑜∆𝑥(𝑇∞ − 𝑇23 )+ k +k
2 ∆𝑥 2 ∆𝑥
2 ∆𝑦 2 ∆𝑡 𝑖 − 𝑇𝑖
𝑇18 23 2∆𝑡 𝑖
𝑖+1 𝑖
𝑖 − 𝑇𝑖
𝑇18 19
𝑖 − 𝑇𝑖
∆𝑥 𝑇14 19 + k∆𝑥 ) ) + 𝑇23
𝑇19 = ((ℎ𝑖∆𝑦(𝑇ℎ − 𝑇19 ) + k∆𝑦 +k ∆𝑦 𝜌∁∆𝑥∆𝑦
∆𝑥 2 ∆𝑦
𝑖 − 𝑇𝑖
∆𝑥 𝑇24 2∆𝑡
T[23][i+1] = (( (ho*x*(Ta-
19 𝑖
+k ) ) + 𝑇19 T[23][i]))+(0.5*k*y*(T[22][i]-T[23][i])/x)+(
2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[19][i+1] = (( (hi*y*(Th- 0.5*k*y*(T[24][i]-T[23][i])/x)+ (k*x*(T[18][i]-
T[19][i]))+(k*y*(T[18][i]-T[19][i])/x)+ T[23][i])/y))*((2*t)/(r*c*x*y))) +T[23][i];
(0.5*k*x*(T[14][i]-T[19][i])/y)+( 0.5*k*x*(T[24][i]-
T[19][i])/y)) *((2*t)/(r*c*x*y))) +T[19][i]; Node 24:
∆𝑥 ∆𝑦 𝑖 − 𝑇𝑖
∆𝑦 𝑇23
𝑖 𝑖 24
ℎ𝑜 (𝑇∞ − 𝑇24 )+ ℎ𝑖 (𝑇ℎ − 𝑇24 )+k +
2 2 2 ∆𝑥
Node 20: 𝑖 − 𝑇𝑖
∆𝑥 𝑇19 ∆𝑥 ∆𝑦 𝑖+1 −𝑇 𝑖
𝑇24
24 24
∆𝑥 𝑖 ∆𝑦 𝑖
𝑖 − 𝑇𝑖
∆𝑦 𝑇21 20
k =𝜌 ∁
ℎ𝑜 (𝑇∞ − 𝑇20 )+ ℎ𝑜 (𝑇∞ − 𝑇20 )+k + 2 ∆𝑦 2 2 ∆𝑡
2 2 2 ∆𝑥 𝑖+1 ∆𝑥 𝑖 ∆𝑦 𝑖
𝑖 − 𝑇𝑖
∆𝑥 𝑇15 ∆𝑥 ∆𝑦 𝑖+20 −𝑇 𝑖
𝑇20 𝑇24 = ((ℎ𝑜 (𝑇∞ − 𝑇24 )+ ℎ𝑖 (𝑇ℎ − 𝑇24 )+
k 20
=𝜌 ∁ 20 2 2
2 ∆𝑦 2 2 ∆𝑡 𝑖 − 𝑇𝑖
∆𝑦 𝑇23 𝑖 − 𝑇𝑖
∆𝑥 𝑇19 4∆𝑡
24 24 𝑖
𝑖+20 ∆𝑥 𝑖 ∆𝑦 𝑖
k +k ) ) + 𝑇24
𝑇20 = ((ℎ𝑜 (𝑇∞ − 𝑇20 )+ ℎ𝑜 (𝑇∞ − 𝑇20 )+ 2 ∆𝑥 2 ∆𝑦 𝜌∁∆𝑥∆𝑦
2 2
𝑖 − 𝑇𝑖
∆𝑦 𝑇21 𝑖 − 𝑇𝑖
∆𝑥 𝑇15 4∆𝑡
T[24][i+1] = (( (0.5*ho*x*(Ta-T[24][i]))+(
20 20 𝑖
k +k ) ) + 𝑇20 0.5*hi*y*(Th-T[24][i])) +(0.5*k*y*(T[23][i]-
2 ∆𝑥 2 ∆𝑦 𝜌∁∆𝑥∆𝑦
T[20][i+1] = (( (0.5*ho*x*(Ta-T[20][i]))+( T[24][i])/x)+ (0.5*k*x*(T[19][i]-
0.5*ho*y*(Ta-T[20][i]))+(0.5*k*y*(T[21][i]- T[24][i])/y))*((4*t)/(r*c*x*y)))
T[20][i])/x)+ (0.5*k*x*(T[15][i]- +T[24][i];
T[20][i])/y))*((4*t)/(r*c*x*y))) +T[20][i];
Node 21:
𝑖 − 𝑇𝑖
∆𝑦 𝑇20 𝑖 − 𝑇𝑖
∆𝑦 𝑇22 III. PROGRAMMING & SOLUTION
𝑖 21 21
ℎ𝑜∆𝑥(𝑇∞ − 𝑇21 )+ k +k +
2 ∆𝑥 2 ∆𝑥
𝑖 − 𝑇𝑖
𝑇16 𝑖+1 −𝑇 𝑖
∆𝑦 𝑇21
21 21 With the help of a computer program we can
k∆𝑥 = 𝜌∆𝑥 ∁
∆𝑦 2 ∆𝑡 solve the matrix created by finite difference equations
𝑖 − 𝑇𝑖
∆𝑦 𝑇20 𝑖 − 𝑇𝑖
∆𝑦 𝑇22
𝑖+1 𝑖 21 21 for 24 nodes. We can calculate temperature distribution
𝑇21 = ((ℎ𝑜∆𝑥(𝑇∞ − 𝑇21 )+ k +k
2 ∆𝑥 2 ∆𝑥 and stress distribution with respect to time.
𝑖 − 𝑇𝑖
𝑇16 2∆𝑡
21 𝑖
+ k∆𝑥 ) )+ 𝑇21
∆𝑦 𝜌∁∆𝑥∆𝑦
Table 1
T[21][i+1] = (( (0.5*ho*x*(Ta- Material Property And Boundary Conditions
T[21][i]))+(0.5*k*y*(T[20][i]-T[21][i])/x)+( Material Properties and Boundary Conditions Unit
0.5*k*y*(T[22][i]-T[21][i])/x)+ (k*x*(T[16][i]- for Magnesia Ramming Mass
T[21][i])/y))*((2*t)/(r*c*x*y))) +T[21][i]; 1 Internal Film Co-efficient 200 W/m2 K
hi
Node 22: 2 External Film Co-efficient 40 W/m2 K
𝑖 − 𝑇𝑖
∆𝑦 𝑇21 𝑖 − 𝑇𝑖
∆𝑦 𝑇23 ho
𝑖 22 22
ℎ𝑜∆𝑥(𝑇∞ − 𝑇22 )+ k +k + 3 Atmosphere Film Co- 10 W/m2 K
2 ∆𝑥 2 ∆𝑥
𝑖 − 𝑇𝑖
𝑇17 𝑖+1 −𝑇 𝑖
∆𝑦 𝑇22
22 22 efficient ha
k∆𝑥 = 𝜌∆𝑥 ∁
∆𝑦 2 ∆𝑡 4 Density 3300 Kg/m3
𝑖 − 𝑇𝑖 𝑖 − 𝑇𝑖
𝑖+1 𝑖 ∆𝑦 𝑇21 22 ∆𝑦 𝑇23 22 5 Time Interval Δt 10 Seconds
𝑇22 = ((ℎ𝑜∆𝑥(𝑇∞ − 𝑇22 )+ k +k
2 ∆𝑥 2 ∆𝑥 6 Thermal Conductivity k 4 W/m K
𝑖 − 𝑇𝑖
𝑇17 2∆𝑡
22 𝑖
+ k∆𝑥 ) )+ 𝑇22 7 Temperature outside 303 Kelvin
∆𝑦 𝜌∁∆𝑥∆𝑦 Furnace Wall
T[22][i+1] = (( (ho*x*(Ta- 8 Temperature inside Furnace 1773 Kelvin
T[22][i]))+(0.5*k*y*(T[21][i]-T[22][i])/x)+( Wall
0.5*k*y*(T[23][i]-T[22][i])/x)+ (k*x*(T[17][i]- 9 Temperature of Air 303 Kelvin
T[22][i])/y))*((2*t)/(r*c*x*y))) 10 Specific Heat 880 J/kg K
+T[22][i]; 11 Elasticity Constant 180000 N/ m2
Node 23: 12 Thermal Expansion Co- 0.00000 m/ K
efficient 138
13 Ultimate Stress 600 MPa

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 SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017

IV. RESULTS AND DISCUSSION it starts reducing. There are 10 similar thermal stress
cycles in one day.
Maximum Temperature v/s Time V. CONCLUSION
Magnesia Ramming Mass
1800 Induction melting furnaces are highly used
1600 now-a-days for melting of different kinds of materials.
Temperature (Kelvin)

1400 We have found variation of maximum temperature and

1200 maximum thermal stress with reference to time. From
1000 the graph, we can conclude that induction furnace wall
800 which is made from magnesia ramming mass is under
600 the effect of low cycle thermal fatigue. The reason for
400 its low life span is thermal fatigue behavior of its
200 loading conditions.
0
1

136
181
226
271
316
361
406
451
496
541
586
46
91

VI. FUTURE SCOPE

Time (Minutes) This analysis can be utilized for prediction of
life cycle of induction furnace wall which is made up of
Fig. 2.Maximum Temperature v/s Time Graph for magnesia based refractory materials. It can also be
Magnesia Ramming Mass
utilized to improve efficacy of furnace and optimization
of wall thickness.
We can see from the Fig. 2 that maximum
temperature is increasing from atmospheric temperature REFERENCES
300 K and reaches to maximum temperature 1667 K in
45 minutes and then starts reducing and reaches to 831 [1] Nirajkumar Mehta, (May 2012), “Review on Computational
K in next 15 minutes. It again starts increasing and Investigation on Different Kinds of Furnaces”, International
Conference on Emerging Technologies and Applications in
reaches to maximum 1667 K after 105 minutes and
Engineering, Technology and Sciences, Volume 3, pp 1 – 7.
again starts reducing. There are 10 similar temperature [2] N C Mehta, Vipul B Gondaliya, Jayesh V Gundaniya, (February
cycles in one day. 2013), “Applications of Different Numerical Methods in Heat
Transfer - A Review”, International Journal of Emerging
Technology and Advanced Engineering, Volume 3, Issue 2, pp
Maximum Stress v/s Time Magnesia 363 – 368.
Ramming Mass [3] N C Mehta, Akash D Raiyani, Vikas R Gondalia, (February
2013), “Thermal Fatigue Analysis of Induction Melting Furnace
500 Wall for Silica ramming mass”, International Journal of
Emerging Technology and Advanced Engineering, Volume 3,
400 Issue 2, pp 357 – 362.
Stress (MPa)

[4] Vimal R Nakum, Kevin M Vyas, Niraj C Mehta, (April 2013),

300 “Research on Induction Heating - A Review”, International
Journal of Science and Engineering Applications, Volume 2,
200 Issue 6, pp 141 – 144, DOI: 10.7753/IJSEA0206.1005.
[5] N C Mehta, Viral V Shiyani, Jemish R Nasit, (May 2013),
100
“Metal Forming Analysis”, International Journal of Emerging
0 Technology and Advanced Engineering, Volume 3, Issue 5, pp
190 - 196.
1

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169
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379
421
463
505
547
589
43
85

[6] Vipul Gondaliya, Mehul Pujara, Nirajkumar Mehta, (August

Time (Minutes)
Fig. 3.Maximum Stress v/s Time Graph for Magnesia
Ramming Mass
We can see from the Fig. 3 that maximum
thermal stress is increasing from initial condition 0 MPa
and reaches to maximum stress 414 MPa in 45 minutes
and then starts reducing and reaches to 206 MPa in next
15 minutes. It again starts increasing and reaches to
maximum stress 414 MPa after 105 minutes and again
2013), “Transient Heat Transfer Analysis of Induction Furnace
by Using Finite Element Analysis”, International Journal of
Applied Research, Volume 3, Issue 8, pp 231 – 234.
[7] N C Mehta, Vasim G Machhar, Ravi K Popat, (October 2013),
“Thermal Fatigue Analysis of Induction Furnace Wall for
Alumina ramming mass”, International Journal of Science and
Engineering Applications, Volume 2, Issue 10, pp 186 – 190,
DOI: 10.7753/IJSEA0210.1002.
[8] Akash D Raiyani, N R Sheth, Niraj C Mehta, (July 2014),
“Thermal Analysis of Hot Wall Condenser for Domestic
Refrigerator”, International Journal of Science and Research,
Volume 3, Issue 7, pp 622 – 626.
[9] Nirajkumar C Mehta, Dipesh D Shukla, Ravi K Popat,
(December 2014), Optimisation of Wall Thickness for
Minimum Heat Loss for Induction Furnace by FEA, Indian
Foundry Journal, Volume 60, No. 12, pp 19-25.

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 SSRG International Journal of Thermal Engineering (SSRG-IJTE) Volume 3 Issue 1 Jan to April 2017

[10] Nirajkumar C Mehta, Dr. Dipesh D Shukla, Vishvash B

Rajyaguru, (April 2015), “Numerical Analysis of Furnace:
Review”, National Conference on Recent Research and
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