Numerical and experimental study of pre-forging heating process of heavy-section steel blocks

In forging and rolling processes, methane used in heating furnaces represents the main cost item. For this reason, it is important to reduce its consumption without negatively affecting the quality of final products. By means of experimental investigations (thermo-couples measurements and infrared camera analyses) coupled to a simplified thermal numerical model, it has been possible to study the complete thermal evolution of low carbon steel ingots of various diameters during the heating stage carried out in methane ovens. By evaluating of both experimental and numerical results, the heating cycle has been optimized. Three main aspects were taken into account: the final quality of forgings, energy and heating time reduction. The potential for significant savings in terms of energy and cycle time have been finally evaluated.