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What factors are related to glass breakage in a tempering furnace?
Release time:
2021-04-02
During tempered glass production, operators may encounter glass breakage within the tempering furnace, a phenomenon known as 'furnace explosion,' an abnormality in tempered glass manufacturing. Since the glass breaks inside the furnace, it usually requires cooling, cleaning, and tidying, resulting in significant electricity cost losses for deep-processing companies – often thousands or even tens of thousands of dollars.
The process of cooling down the tempering furnace, cleaning, and reheating for production resumption generally takes at least 24 hours. Therefore, furnace explosions often disrupt production schedules and order delivery.
Furnace explosions are a production abnormality that all processing companies want to prevent but find difficult to avoid. Let's discuss the factors related to furnace explosions:
I. Original Sheet Quality
Glass undergoes rapid heating within the tempering furnace. During this process, the glass endures the impact of thermal stress. As glass is a brittle material, minor cracks can quickly expand under thermal stress, causing the glass to break. It's like a tightly stretched piece of paper; even a small tear will cause it to rip along that tear.
In terms of original sheet quality, inclusions, bubbles, and micro-cracks significantly impact furnace explosions. Furnace explosions during the tempering of glass thicker than 12mm are often caused by defects in the original sheet. Apart from procuring high-quality original sheets, strengthening pre-furnace inspections is crucial.
II. Cold Processing Quality
Cold processing leading to tempering explosions refers to edge cracks caused by grinding, drilling, slotting, etc., resulting in furnace explosions. The edges of the glass experience the greatest thermal stress during the tempering process and are the most susceptible to breakage. Edge grinding of tempered glass is necessary to eliminate cracks caused by cutting.
Drilling and slotting are similar to grinding, aiming to eliminate cracks at the hole or slot locations, otherwise, the glass may also break from the cracks during the heating process.
III. Tempering Process
The tempering process is also a cause of furnace explosions. Improper processes mainly involve two situations: too-rapid heating and uneven heating.
Overly rapid heating is mainly related to excessively high temperature settings and excessive convection. Too-rapid heating causes the glass to heat up too quickly after entering the furnace, resulting in excessive thermal stress and glass breakage. Generally, the thicker and larger the glass, the slower the heating rate should be. Furnace explosions caused by rapid heating usually result in small, fragmented pieces.
Uneven heating refers to differences in heating speed between the upper and lower surfaces of the glass in the tempering furnace. One side heats faster and reaches a higher temperature, while the other heats slower and remains at a lower temperature. In this case, the glass will warp in the tempering furnace; mildly, resulting in roller marks, and severely, causing the glass to collide with the rollers or heating elements and shatter.
Uneven heating is common in LOW-E glass and mainly relies on temperature and convection adjustments; directly observing the state of the glass inside the furnace is an effective way to avoid this issue.
IV. Equipment Malfunction
Equipment malfunctions leading to furnace explosions are usually caused by the transmission system, including common issues such as silicon rod jamming, length measurement abnormalities, and encoder/inverter malfunctions. In addition, breakage of some heating wires or convection fan failure leading to uneven regional temperatures can also easily cause furnace explosions.
The above is a summary of some reasons for glass breakage inside the tempering furnace. For more information, please continue to follow us.
Fracture, glass, heating, causing cracks, abnormal, accelerated process, temperature conditions
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