Finite Element Simulation and Parameter Optimization of SWRH82B Wire Rod in Stelmor Cooling Process

Based on the field production conditions, the air cooling process for SWRH82B in Stelmor was designed and simulated. The temperature variations of the surface and core of both the lap region and non lap region of the wire rod were measured under different cooling conditions, and the discrepancy in cooling between the surface and core was analyzed. A reasonable finite element model was developed and evaluated using ANSYS finite element analysis software to study the temperature field changes of the SWRH82B wire rod during controlled cooling. The node temperature drop curve and transient temperature field distribution of the Φ12.5 mm SWRH82B wire rod during the 880 °C laying process were determined. By adjusting the Optiflex device angle and coil spacing, similar cooling rates for the lapped and non lapped sections were achieved, minimizing temperature differences and improving temperature uniformity. Simulation results indicate that maintaining a 3° opening angle for the Optiflex device of the first four blowers and a 1.5° opening angle for the remaining four blowers resulted in comparable surface temperatures for the wire rod in both lapped and non lapped areas during the air cooling process, with a temperature difference of up to 6 °C. As the initial roller speed increased, the temperature difference on the surface of each wire rod in the lap area firstly decreases and then rise again, reaching a minimum between 0.70 and 0.75 m/s, with a corresponding wire rod spacing between 73.90 and 79.18 mm. Optimization simulation of the laying temperature at 880 °C, demonstrated a SWRH82B microstructure with a 92% sorbite occupancy rate, network cementite below 1 grade, and core martensite less than 0.5 grade.