Convection Heat Transfer in Manufacturing Processes

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

Mode of Heat Transfer due to macro-Movements!!!

Convection Heat Transfer in Manufacturing
 Some thing Happens Before Onset of Convection
Heat Transfer
• The convective heat transfer is defined for a combined solid and
fluid system.
• In a flow system, small layer of fluid particles close to the wall
come to Mechanical, Thermal and Chemical Equilibrium With
solid wall.
• Fundamentally this fluid layer is in Thermodynamic Equilibrium
with the solid wall.
• Physically, the fluid packets close to a solid wall attain a zero
relative velocity with the solid wall.
• The fluid particles will exchange maximum possible heat flux
with the solid wall.
• A Zero temperature difference exists between wall and fluid
packets at the wall.
 Heat Transfer in Equilibrium Fluid Layer
 
At Thermodynamic equilibrium T fluid,wall  Twall & V fluid,wall  Vwall

• The thickness of stagnant layer decides the magnitude of normal

temperature gradient at the wall.
• And hence, the thickness of wall fluid layer decides the magnitude of
rate of heat transfer form wall/to the wall.
• The bulk movement of fluid particles export this heat deep into fluid
body duet to macro motion (convection).
 Conduction Heat Transfer in Equilibrium Fluid Layer
At the surface, there is no fluid motion, heat transfer is only possible due
to heat conduction. Thus, from the local heat flux:
T
''
q wall  k
y y 0
This is the basic mechanism for heat transfer from solid to liquid or
Vice versa.
The heat conducted into the fluid will further propagate into free
stream fluid by convection alone.
Use of Newton’s Law of Cooling: q ''

 h Ts  T 
At the edge of fluid layer :

 T 
 k fluid A   hAT fluid, wall  T 
 y  fluidlayer
 Estimation of Heat Transfer Coefficient
 T 
k fluid  
 y  wall
h
Twall  T 
• Estimation of heat transfer coefficient is basically computation
of temperature profile.
• A general theoretical and experimental study to understand how
the stagnant layer is developed.
• The global geometry of the solid wall and flow conditions will
decide the structure of stagnant layer.
• Basic Geometry : Internal Flow or External Flow.
Structure of Internal Flows
 Temperature Profile in Internal Flow

Hot Wall & Cold Fluid

q’’
Ts(x)
Ti

Cold Wall & Hot Fluid

Ti q’’
Ts(x)
 External Flows
• There will be continuous growth of Solid surface affected
region in Main stream direction.
• The extent of this region is very very small when
compared to the entire flow domain.
• Free stream flow and thermal properties exit during the
entire flow.
 Momentum Transfer near solid Wall
At the surface there is no relative motion between fluid and solid.
The local momentum flux (gain or loss) is defied by
Newton’s Law of Viscosity :

u
 wall 
y y 0

Momentum flux of far field stream:

u2
P '' 
2
The effect of solid boundary :
ratio of shear stress at wall/free stream Momentum flux
Coefficient of friction:

u

 wall y y 0
Cf  
P ''
u 2

2
 Cold Surface Thermal Boundary Layer
Plate surface is cooler than the fluid (Ts < T∞)

T
q  hTs  T  y 
''
 k
y y 0

Scale of temperature: Ts  T  T  Ts 

Define non-dimensional Temperature as:

T  T

Ts  T
 Empirical method
T , U 

Twing surface

• How to set up an experimental test?

• Let’s say you want to know the heat transfer rate of an airplane
wing (with fuel inside) flying at steady conditions………….
• What are the parameters involved?
– Velocity, –plate length,
– Prandtl number, –viscosity,
– Nusselt number,
• Which of these can we control easily?
• Looking for the relation:

Experience has shown the following relation works well:

 Experimental test setup

T , U 

L
insulation

•Measure current (hence heat transfer) with various fluids and test
conditions for
•Fluid properties are typically evaluated at the mean film
temperature
Study of Convection Heat Transfer
Similarity Variables
Reynolds number : An Universal Measure Flow

All Engineering Applications

 Potential for diffusion of momentum change (Deficit or excess) created
by a solid boundary.

Potential for Diffusion of thermal changes created by a solid boundary.

 * dp *

  f  x , Re L , * , Pr 
 dx 
Prandtl Number: The ratio of momentum diffusion to heat diffusion.
 m
Pr  
 T
Other scales of reference:

Length of plate: L

Free stream velocity : uoo

Local convection heat transfer coefficient:

 T  Ts  
hTs  T   k fluid   *
 L  y y* 0

k fluid  hx L 
hx   *
L y * y* 0
k fluid y y* 0

For a hot horizontal flat plate

hx x
Nux   0.332 Re x pr1/ 3
k fluid
Average heat transfer coefficient:
L L
1 1 k fluid
havg   hx dx   0.332 Re x pr1/ 3dx
L0 L0 x

L
1 k fluid u 1/ 3 dx
havg  0.332 pr 
L x  0 x

havg  2hx

havg L
Nuavg   0.664 Re L pr 1/ 3 pr  0.6
k fluid
Complex Heat Convection Geometries in
Manufacturing
 Cylinder in Cross Flow

14
hD 1 3  Pr 
Nu D   C Re D Pr 
m

k  Prs 
0.7  Pr  500
Valid for :  6
1  Re D  10 
 Cylinder in Cross Flow

The empirical correlation due to Hilpert

hD
Nu D   C Re mD Pr1/ 3
k
ReD C m
0.4 -4 0.989 0.330
4 - 40 0.911 0.385
40 -- 4000 0.683 0.466
4000 -- 40000 0.193 0.618
40000 -- 400000 0.027 0.805