Numerical simulation of melt flow and temperature field during DC casting 2024 aluminium alloy under different casting conditions

Casting speed,casting temperature and secondary cooling water flow rate are the main process parameters affecting the DC casting process.These parameters significantly influence the flow and temperature fields during casting,which are crucial for the quality of the ingot and can determine the success or failure of the casting operation.Numerical simulation,with the advantages of low cost,rapid execution,and visualized results,is an important method to study and optimize the DC casting process.In the present work,a simulation model of DC casting 2024 aluminum alloy was established,and the reliability of the model was verified.Then,the influence of casting parameters on flow field and temperature field was studied in detail by numerical simulation method.Results show that with the increase of casting speed,the melt flow becomes faster,the depths of slurry zone and mushy zone increase,and the variation of slurry zone depth is greater than that of mushy zone.With an increase in casting temperature,the melt flow rate increases,the depth of the slurry zone becomes shallower,and the depth of the mushy zone experiences only minor changes.The simulation results further indicate that the increase of the flow rate of the secondary cooling water slightly reduces the depths of both slurry and mushy zone.

Stability analysis of a liquid crystal elastomer self-oscillator under a linear temperature field

Self-oscillating systems abound in the natural world and offer substantial potential for applications in controllers,micro-motors,medical equipments,and so on.Currently,numerical methods have been widely utilized for obtaining the characteristics of self-oscillation including amplitude and frequency.However,numerical methods are burdened by intricate computations and limited precision,hindering comprehensive investigations into self-oscillating systems.In this paper,the stability of a liquid crystal elastomer fiber self-oscillating system under a linear temperature field is studied,and analytical solutions for the amplitude and frequency are determined.Initially,we establish the governing equations of self-oscillation,elucidate two motion regimes,and reveal the underlying mechanism.Subsequently,we conduct a stability analysis and employ a multi-scale method to obtain the analytical solutions for the amplitude and frequency.The results show agreement between the multi-scale and numerical methods.This research contributes to the examination of diverse self-oscillating systems and advances the theoretical analysis of self-oscillating systems rooted in active materials.

Investigation on Temperature Field Calibration and Analysis of Wind Tunnel

For wind tunnels,it is essential to conduct temperature and flow field calibration on their test section,which is an important indicator for evaluating the quality of wind tunnel flow fields.In the paper,a truss composed of temperature sensors was used to calibrate the temperature field of a completed wind tunnel section.By adjusting the distance between the temperature measurement truss and the nozzle,as well as the wind speed,the temperature field distribution data at different positions could be obtained.Analyze these data to identify important factors that affect the distribution of temperature field.Simultaneously,the temperature field of the wind tunnel was simulated accordingly.The purpose is to further analyze the fluid heat transfer between air and wind tunnel walls through numerical simulation.Through the above analysis methods,the quality of the temperature field in the wind tunnel has been further verified,providing reference for future wind tunnel tests of relevant models.

Temperature field calculation of rail flash welding

The forging stage of rail flash welding has a decisive influence on joint strength,and the study of the temperature distribution in the process has an important role in further improving joint strength.In this paper,three calculation methods for the temperature field are given.First,the finite element model of the temperature field before forging rail flash welding is established by using the transient heat module of Ansys software and verified by infrared temperature measurement.Second,the temperature distribution of different parts of the rail before flash welding is obtained by using infrared thermal imaging equipment.Third,Matlab software is used to calculate the temperature of the non-measured part.Finally,the temperature distribution function along the rail axis is fitted through the temperature measurement data.The temperature distribution before the top forging of the rail flash welding can be used to analyze the joint and heat-affected zone organization and properties effectively and to guide the parameter setting and industrial production.

Temperature field model in surface grinding: a comparative assessment

Grinding is a crucial process in machining workpieces because it plays a vital role in achieving the desired precision and surface quality.However,a significant technical challenge in grinding is the potential increase in temperature due to high specific energy,which can lead to surface thermal damage.Therefore,ensuring control over the surface integrity of workpieces during grinding becomes a critical concern.This necessitates the development of temperature field models that consider various parameters,such as workpiece materials,grinding wheels,grinding parameters,cooling methods,and media,to guide industrial production.This study thoroughly analyzes and summarizes grinding temperature field models.First,the theory of the grinding temperature field is investigated,classifying it into traditional models based on a continuous belt heat source and those based on a discrete heat source,depending on whether the heat source is uniform and continuous.Through this examination,a more accurate grinding temperature model that closely aligns with practical grinding conditions is derived.Subsequently,various grinding thermal models are summarized,including models for the heat source distribution,energy distribution proportional coefficient,and convective heat transfer coefficient.Through comprehensive research,the most widely recognized,utilized,and accurate model for each category is identified.The application of these grinding thermal models is reviewed,shedding light on the governing laws that dictate the influence of the heat source distribution,heat distribution,and convective heat transfer in the grinding arc zone on the grinding temperature field.Finally,considering the current issues in the field of grinding temperature,potential future research directions are proposed.The aim of this study is to provide theoretical guidance and technical support for predicting workpiece temperature and improving surface integrity.

Temperature Field in Laser Line Scanning Thermography: Analytical Calculation and Experiment

The temperature field in laser line scanning thermography is investigated comprehensively in this work,including analytical calculation and experiment.Firstly,the principle of laser line scanning thermography is analyzed.On this basis,a physical laser line scanning model is proposed.Afterwards,based on Fourier transform(FT)and segregation variablemethod(SVM),the heat conduction differential equation in laser line scanning thermography is derived in detail.The temperature field of the composite-based coatings model with defects is simulated numerically.The results show that the laser line scanning thermography can effectively detect the defects in the model.The correctness of the analytical calculation is verified by comparing the surface temperature distribution obtained by analytical calculation and numerical simulation.Additionally,an experiment is carried out and the changeable surface temperature obtained by analytical calculation is compared with the experimental results.It shows that the error of maximum temperature obtained by analytical calculation and by experiment is 8%with high accuracy,which proves the correctness of analytical calculation and enriches the theoretical foundation of laser line scanning thermography.

Thermal Properties Reconstruction and Temperature Fields in Asphalt Pavements: Inverse Problem and Optimisation Algorithms

A two-layer implicit difference scheme is employed in the present study to determine the temperature distribution in an asphalt pavement.The calculation of each layer only needs four iterations to achieve convergence.Furthermore,in order to improve the calculation accuracy a swarm intelligence optimization algorithm is also exploited to inversely analyze the laws by which the thermal physical parameters of the asphalt pavement materials change with temperature.Using the basic cuckoo and the gray wolf algorithms,an adaptive hybrid optimization algorithm is obtained and used to determine the relationship between the thermal diffusivity of two types of asphalt pavement materials and the temperature.As shown by the results,the prediction accuracy achievable with this approach is higher than that of the linear model.

Numerical analysis for permafrost temperature field in the short term of permafrost subgrade filling

Purpose-It is of great significance to study the influence of subgrade filling on permafrost temperature field in permafrost area for the smooth construction and safe operation of railway.Design/methodology/approach-The paper builds up the model for the hydrothermal coupling calculation of permafrost using finite element software COMSOL to study how permafrost temperature field changes in the short term after subgrade filling,on which basis it proposes the method of calculation for the concave distortion of freezing front in the subgrade-covered area.Findings-The results show that the freezing front below the subgrade center sinks due to the thermal effect of subgrade filling,which will trigger hydrothermal erosion in case of sufficient moisture inflows,leading to the thawing settlement or the cracking of the subgrade,etc.The heat output of soil will be hindered the most in case of July filling,in which case the sinking and the distortion of the freezing front is found to be the most severe,which the recovery of the permafrost temperature field,the slowest,constituting the most unfavorable working condition.The concave distortion of the freezing front in the subgrade area increases with the increase in temperature difference between the filler and ground surface,the subgrade height,the subgrade width and the volumetric thermal capacity of filler,while decreases with the increase of the thermal conductivity of filler.Therefore,the filler chose for engineering project shall be of small volumetric thermal capacity,low initial temperature and high thermal conductivity whenever possible.Originality/value-The concave distortion of the freezing front under different working conditions at different times after filling can be calculated using the method proposed.

Calculation of Mass Concrete Temperature and Creep Stress under the Influence of Local Air Heat Transfer

Temperature-induced cracking during the construction of mass concrete is a significant concern.Numerical simulations of concrete temperature have primarily assumed that the concrete is placed in an open environment.The problem of heat transfer between the air and concrete has been simplified to the concrete’s heat dissipation boundary.However,in the case of tubular concrete structures,where air inlet and outlet are relatively limited,the internal air temperature does not dissipate promptly to the external environment as it rises.To accurately simulate the temperature and creep stress in tubular concrete structures with enclosed air spaces during construction,we establish an air–concrete coupled heat transfer model according to the principles of conjugate heat transfer,and the accuracy of the model is verified through experiments.Furthermore,we conduct a case study to analyze the impact of airflow within the ship lock corridor on concrete temperature and creep stress.The results demonstrate that enhancing airflow within the corridor can significantly reduce the maximum concrete temperature.Compared with cases in which airflow within the corridor is neglected,the maximum concrete temperature and maximum tensile stress can be reduced by 12.5℃ and 0.7 MPa,respectively,under a wind speed of 4 m/s.The results of the traditional calculation method are relatively close to those obtained at a wind speed of 1 m/s.However,the temperature reduction process in the traditional method is faster,and the method yields greater tensile stress values for the corridor location.

The Effects of Thickness and Location of PCMon the Building’s Passive Temperature-Control–A Numerical Study

Building energy consumption and building carbon emissions both account for more than 20%of their total national values in China.Building employing phase change material(PCM)for passive temperature control shows a promising prospect in meeting the comfort demand and reducing energy consumption simultaneously.However,there is a lack of more detailed research on the interaction between the location and thickness of PCM and indoor natural convection,as well as indoor temperature distribution.In this study,the numerical model of a passive temperature-controlled building integrating the developed PCM module is established with the help of ANSYS.In which,the actual weather condition of Beijing city is set as the boundary conditions and the indoor natural convection is simulated with the consideration of radiation model.The effects of PCM’s thickness and location on the internal temperature field are analyzed and discussed.The results show that the room could maintain within the human comfort temperature range with the longest ratio of 94.10%and the shortest ratio of 51.04%as integrating PCM.In comparison,the value is only 26.70%without PCM.The room’s maximum temperature fluctuation can also be improved;it could be lowered by 64.4%compared to the normal condition.When the quantity of PCM is sufficient,further increasing the PCM amount results in a temperature fluctuation reduction of less than 0.1°C and does not increase the comfort time.Placing PCM on the wall induces an apparent variation in indoor temperature along the vertical direction.Conversely,placing PCM on the roof can lead to a heat transfer rate difference of up to seven times.The optimal placement of PCM depends on the difference between the environmental and phase change temperatures.If the difference is positive,placing PCM on the roof is more effective;conversely,the opposite holds.According to the results over the entire cycle,PCM application on vertical walls yields better performance.The significant difference in natural convection caused by the same thickness of PCM but different application positions,coupled with the influence of air movement on the melting and solidification of PCM,further impacts indoor temperature fluctuations and comfort.This study can provide guidance for the application location and thickness of PCM,especially for scenarios where temperature regulation is required at a specific time.

Temperature and stress fields in electron beam welded Ti-15-3 alloy to 304 stainless steel joint with copper interlayer sheet

Electron beam welding of Ti-15-3 alloy to 304 stainless steel （STS） using a copper filler metal was carried out. The temperature fields and stress distributions in the Ti/Fe and Ti/Cu/Fe joint during the welding process were numerically simulated and experimentally measured. The results show that the rotated parabola body heat source is fit for the simulation of the electron beam welding. The temperature distribution is asymmetric along the weld center and the temperature in the titanium alloy plate is higher than that in the 304 STS plate. The thermal stress also appears to be in asymmetric distribution. The residual tensile stress mainly exists in the weld at the 304 STS side. The copper filler metal decreases the peak temperature and temperature grade in the joint as well as the residual stress. The longitudinal and lateral residual tensile strengths reduce by 66 MPa and 31 MPa, respectively. From the temperature and residual stress, it is concluded that copper is a good filler metal candidate for the electron beam welding of Ti-15-3 titanium alloy to 304 stainless steel.

NUMERICAL SIMULATIONS OF TEMPERATURE FIELD IN DIRECT METAL LASER SINTERING PROCESS

A mathematical model is developed for simulating the heat transferring behavior in a direct metal laser sintering process. The model considers the thermal phenomena involved in the process, including conduction, radiation, and convection. A formula for the calculation of the heat conductivity of a sintering system containing solid phase, liquid phase, and gas phase is given. Due to the continuous movement of the laser beam, a local coordinate system centered on the laser beam is used to simplify the analytical calculation. Assuming that it is approximately a Gaussian laser beam, the heat conduction equation is resolved based on the assumption of the thermal insulating boundary conditions and the fixed thermal physical parameters. The FORTRAN language is employed to compile the program to simulate the temperature field in the direct copper powder sintering process. It shows a good agreement with the preliminary experimental results.[KH3/4D]

Analysis of Static Temperature Field of Vehicle's Solid Rubber Tire

Aim To analyse the static temperature field ofthe solid rubber tire(SRT).Methods The mechanical and thermal FE models were developed and analyzed respectively with the FE software ANSYS.Results The maximum temperature becomes higher with the higher with the higher velocity of tire and scales down slightly with the higher convection coefficients.The mixed models are reasonable.Conclusion The study on static temperature field is important and reasonable.It gives the fundament for life analysis of SRT.

Measurement and theoretical analysis of solar temperature field in steel-concrete composite girder

The solar temperature field of a large three-span continuous bridge with steel-concrete composite box girder and variable cross-section is measured to verify a calculation method for the temperature field of steel-concrete composite beams. The test results show that the temperature of an external steel web- plate is higher than that of an internal web-plate due to the difference in solar radiation. Air temperature inside the box matches the average temperature of the whole steel box. Based on actual measurements, a transient thermal analysis with multiple boundary conditions is also carried out by a software program ANSYS. Convective boundary situation and states of solar radiation on steel web plates in different situations are determined in the analysis. The feature of the temperature field is preliminarily achieved through a comparative study between the actual measurement and the finite element analysis. The computed results are in good consistence with the actual measurement results, with the maximum difference within 2 ℃. This indicates that the theoretical calculation method is reliable and it provides a foundation for further research on temperature field distribution in the steel-concrete composite box girder.

TRANSIENT TEMPERATURE FIELD IN ACTIVE THRUST MAGNETIC BEARING

A transient temperature field model in a thrust magnetic bearing is built in which the heat resources come mainly from the eddy-current loss of solid cores and the copper loss of coils. The transient temperature field, system temperature rise and the thermo-equilibrium state during the rotor starting-up are calculated considering only the copper loss and the eddy-current loss. The numerical results indicate that the temperatures in coils and in magnets rise rapidly, their thermo-equilibrium states are formed within a short time. The temperatures in a thrust-disk and in a rotor rise slowly, their thermo-equilibrium states are formed aller a long period time. The temperatures of the thrust-disk and the rotor are far higher than the temperatures of coils and/or magnets aller the thermo-equilibrium state has come into being.

STUDY ON TEMPERATURE FIELD INDUCED IN HIGH FREQUENCY INDUCTION HEATING

A mathematical model was established for the temperature field developed during high frequency induction heating （HFIH） by Maxwell＇s equations. It required solving the coupled equations of the electromagnetic and temperature fields. The numerical simudation was performed using FEMLAB. The comparison of the calculations using the proposed model with experimental results showed a very good correlation. The effects of the heating parameters in high frequency induction such as the distance between the plate and the coil, the applied current, the frequency, and the turns of the coil on the temperature profiles developed in the plate were also discussed using the established model.

Numerical Simulation of Temperature Field and Thermal Stress Field of Work Roll During Hot Strip Rolling

Based on the thermal conduction equations, the three-dimensional （3D） temperature field of a work roll was investigated using finite element method （FEM）. The variations in the surface temperature of the work roll during hot strip rolling were described, and the thermal stress field of the work roll was also analyzed. The results showed that the highest roll surface temperature is 593 ℃, and the difference between the minimum and maximum values of thermal stress of the work roll surface is 145.7 MPa. Furthermore, the results of this analysis indicate that temperature and thermal stress are useful parameters for the investigation of roll thermal fatigue and also for improving the quality of strip during rolling.

Numerical simulation of the temperature fields of stainless steel with different roller parameters during twin-roll strip casting

The temperature field of stainless steel during twin-roll strip casting was simulated by experiment and a finite element （FE） model. By comparing the measured result with the simulated values, it is found that they fit close to each other, which indicates this FE model is effective. Based on this model, the effects of roll gap （t） and roll radius （R） on solidification were simulated. The simulated results give the relationship between t or R and the position of the freezing point. The larger the t is and the smaller the R is, the closer the position of the freezing point is to the exit.

THE COUPLED FEM ANALYSIS OF THE TRANSIENT TEMPERATURE FIELD DURING INERTIA FRICTION WELDING OF GH4169 ALLOY

The inertia friction welding process is a non-linear process because of the interaction between the temperature field and the material properties as well as the friction force. A thermo-mechanical coupled finite element model is established to simulate the temperature field of this process. The transient temperature distribution during the inertia friction welding process of two similar workpieces of GH4169 alloy is calculated. The region of the circular cross-section of the workpiece is divided into a number of four-nodded isoparametric elements. In this model, the temperature dependent thermal properties, time dependent heat inputs, contact condition of welding interface, and deformation of the flash were considered. At the same time, the convection and radiation heat losses at the surface of the workpieces were also considered. A temperature data acquisition system was developed. The temperature at some position near the welding interface was measured using this system. The calculated temperature agrees well with the experimental data. The deformation of the flash and the factor affecting the temperature distribution at the welding interface are also discussed.

COUPLED NUMERICAL SIMULATION ON COLD ROLLER'S TEMPERATURE FIFLD-PHASE TRANSFORMATION - STRESS FIELD DURING ITS QUENCHING PSOCESS

Complicated changns occur inside the steel parts during quenching process. The abruptly changed boundary conditions make the temperature field,micro - structure and stress field change dramatically in very short time, and these variables take a contact interactions in the whole process. In this paper, a three dimensional non - linear mathematical model for queeching process has been founded and the numerical simulation on temperature field,microstructre and stress field has been realized.In the FEM analysis, the incremental iteration method is used to deal with such complicated nonlinear as boundary nonlinear, physical property nonlinear,transformation nonlinear etc.The effect of stress on transformation kinetics has been considered in the calculation of microstructure. In the stress field anal- ysis,a thermo- elasto - plastic model has been founded, which considers such factors as transforma- tion strain,transformation plastic strain, themal strain and the effect of temperature and transforma- tion on mechanical propertier etc. The transient temperature field, microstructure distribution and stress field of the roller on any time can be displayed vividly,and the cooling curve and the changes of stress on any position can also be given.