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.

Gyro-Landau-fluid simulations of impurity effects on ion temperature gradient driven turbulence transport

The effects of impurities on ion temperature gradient(ITG)driven turbulence transport in tokamak core plasmas are investigated numerically via global simulations of microturbulence with carbon impurities and adiabatic electrons.The simulations use an extended fluid code(ExFC)based on a four-field gyro-Landau-fluid(GLF)model.The multispecies form of the normalized GLF equations is presented,which guarantees the self-consistent evolution of both bulk ions and impurities.With parametric profiles of the cyclone base case,well-benchmarked ExFC is employed to perform simulations focusing on different impurity density profiles.For a fixed temperature profile,it is found that the turbulent heat diffusivity of bulk ions in a quasi-steady state is usually lower than that without impurities,which is contrary to the linear and quasilinear predictions.The evolutions of the temperature gradient and heat diffusivity exhibit a fast relaxation process,indicating that the destabilization of the outwardly peaked impurity profile is a transient state response.Furthermore,the impurity effects from different profiles can obviously influence the nonlinear critical temperature gradient,which is likely to be dominated by linear effects.These results suggest that the improvement in plasma confinement could be attributed to the impurities,most likely through adjusting both heat diffusivity and the critical temperature gradient.

The Relation between Mental Workload and Face Temperature in Flight Simulation

In this research, we study the relationship between mental workload and facial temperature of aircraft participants during a simulated takeoff flight. We conducted experiments to comprehend the correlation between work and facial temperature within the flight simulator. The experiment involved a group of 10 participants who played the role of pilots in a simulated A-320 flight. Six different flying scenarios were designed to simulate normal and emergency situations on airplane takeoff that would occur in different levels of mental workload for the participants. The measurements were workload assessment, face temperatures, and heart rate monitoring. Throughout the experiments, we collected a total of 120 instances of takeoffs, together with over 10 hours of time-series data including heart rate, workload, and face thermal images and temperatures. Comparative analysis of EEG data and thermal image types, revealed intriguing findings. The results indicate a notable inverse relationship between workload and facial muscle temperatures, as well as facial landmark points. The results of this study contribute to a deeper understanding of the physiological effects of workload, as well as practical implications for aviation safety and performance.

Numerical simulation of downhole temperature distribution in producing oil wells

An improved numerical simulation method is presented to calculate the downhole temperature distribution for multiple pay zones in producing oil wells. Based on hydrodynamics and heat transfer theory, a 2-D temperature field model in cylindrical coordinates is developed. In the model, we considered general heat conduction as well as the heat convection due to fluid flow from porous formation to the borehole. We also take into account the fluid velocity variation in the wellbore due to multiple pay zones. We present coupled boundary conditions at the interfaces between the wellbore and adjacent formation, the wellbore and pay zone, and the pay zone and adjacent formation. Finally, an alternating direction implicit difference method （ADI） is used to solve the temperature model for the downhole temperature distribution. The comparison of modeled temperature curve with actual temperature log indicates that simulation result is in general quite similar to the actual temperature log. We found that the total production rate, production time, porosity, thickness of pay zones, and geothermal gradient, all have effects on the downhole temperature distribution.

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]

Simulation study on non-linear effects of initial melt temperatures on microstructures during solidification process of liquid Mg_7Zn_3 alloy

The non-linear effects of different initial melt temperatures on the microstructure evolution during the solidification process of liquid Mg7Zn3 alloys were investigated by molecular dynamics simulation, The microstructure transformation mechanisms were analyzed by several methods. The system was found to be solidified into amorphous structures from different initial melt temperatures at the same cooling rate of 1×10^12 K/s, and the 1551 bond-type and the icosahedron basic cluster （12 0 12 0 ） played a key role in the microstructure transition. Different initial melt temperatures had significant effects on the final microstructures. These effects only can be clearly observed below the glass transition temperature Tg; and these effects are non-linearly related to the initial melt temperatures, and fluctuated in a certain range. However, the changes of the average atomic energy of the systems are still linearly related with the initial melt temperatures, namely, the higher the initial melt temperature is, the more stable the amorphous structure is and the stronger the glass forming ability will be.

Study on kinetics of propylene polymerizationat different temperatures via Monte Carlo simulation

The elementary reactions of propylene polymerization catalyzed by conventional Ziegler-Natta catalysts was proposed according to the comprehensive view and without considering the effect of any impurity in the material on propylene polymerization. The Monte Carlo simulation technique was employed to investigate the kinetics of propylene polymerization in order to determine the validity of the stationary state assumption and the effects of the polymerization temperature on the polymerization. The simulated total amount of active species, which only increases quickly at the beginning of the polymerization, indicates that the stationary state assumption in the studied system is valid. Moreover, significant effects of polymerization temperature on the polymerization conversion, and the molecular weight and its distribution were also analyzed. The simulated results show that the consumption rate of propylene increases with the increase of polymerization temperature; the maximum values of the number-average degree of polymerization are constant at different polymerization temperatures, however, the peak appears earlier with the higher temperature; as the polymerization temperature increases, the average molecular weight decreases and the molecular weight distribution changes greatly.

Calculation of effective temperature for pavement rutting using numerical simulation methods

In order to predict the long-term rutting of asphalt pavement, the effective temperature for pavement rutting is calculated using the numerical simulation method. The transient temperature field of asphalt pavement was simulated based on actual meteorological data of Nanjing. 24-hour rutting development under a transient temperature field was calculated in each month. The rutting depth accumulated under the static temperature field was also estimated and the relationship between constant temperature parameters was analyzed. Then the effective temperature for pavement rutting was determined based on the rutting equivalence principle. The results show that the monthly effective temperature is above 40 t in July and August, while in June and September it ranges from 30 to 40 Rutting development can be ignored when the monthly effective temperature is less than 30 t. The yearly effective temperature for rutting in Nanjing is around 38. 5 t. The long-term rutting prediction model based on the effective temperature can reflect the influences of meteorological factors and traffic time distribution.

Numerical Simulation of Multi-track and Multi-layer Temperature Field on Laser Direct Metal Shaping

To improve the mechanical properties of the parts fabricated by Laser Direct Metal Shaping(LDMS),it is of great significance to understand the distribution regularities of transient temperature field during LDMS process.Based on the“el- ement birth and death”technique of finite element method,a three-dimensional multi-track and multi-layer model for the transient temperature field analysis of LDMS is developed by ANSYS Parametric Design Language(APDL)for the first time.In the fab- ricated modal,X-direction parallel reciprocating scanning paths is introduced.Using the same process parameters,the simulation results show good agreement with the microstructure features of samples which fabricated by LDMS.

Surface Air Temperature Simulations over China with CMIP5 and CMIP3

Historical simulations of annual mean surface air temperature over China with 25 CMIP5 models were assessed.The observational data from CRUT3v and CN05 were used and further compared with historical simulations of CMIP3.The results show that CMIP5 models were able to simulate the observed warming over China from 1906 to 2005(0.84 C per 100 years)with a warming rate of 0.77 C per 100 years based on the multi-model ensemble(MME).The simulations of surface air temperature in the late 20th century were much better than those in the early 20th century,when only two models could reproduce the extreme warming in the 1940s.The simulations for the spatial distribution of the 20-yearmean(1986–2005)surface air temperature over China fit relatively well with the observations.However,underestimations in surface air temperature climatology were still found almost all over China,and the largest cold bias and simulation uncertainty were found in western China.On sub-regional scale,northern China experienced stronger warming than southern China during 1961–1999,for which the CMIP5 MME provided better simulations.With CMIP5 the diference of warming trends in northern and southern China was underestimated.In general,the CMIP5 simulations are obviously improved in comparison with the CMIP3 simulations in terms of the variation in regional mean surface air temperature,the spatial distribution of surface air temperature climatology and the linear trends in surface air temperature all over China.

Impact of Rain Snow Threshold Temperature on Snow Depth Simulation in Land Surface and Regional Atmospheric Models

This study investigates the impact of rain snow threshold （RST） temperatures on snow depth simulation using the Community Land Model （CLM） and the Weather Research and Forecasting model （WRF--coupled with the CLM and hereafter referred to as WRF_CLM）, and the difference in impacts. Simulations were performed from 17 December 1994 to 30 May 1995 in the French Alps. Results showed that both the CLM and the WRF_CLM were able to represent a fair simulation of snow depth with actual terrain height and 2.5~C RST temperature. When six RST methods were applied to the simulation using WRF_CLM, the simulated snow depth was the closest to observations using 2.5~C RST temperature, followed by that with Pipes＇, USACE, Kienzle＇s, Dai＇s, and 0~C RST temperature methods. In the case of using CLM, simulated snow depth was the closest to the observation with Dai＇s method, followed by with USACE, Pipes＇, 2.5~C RST temperature, Kienzle＇s, and 0~C RST temperature method. The snow depth simulation using the WRF_CLM was comparatively sensitive to changes in RST temperatures, because the RST temperature was not only the factor to partition snow and rainfall. In addition, the simulated snow related to RST temperature could induce a significant feedback by influencing the meteorological variables forcing the land surface model in WRF_CLM. In comparison, the above variables did not change with changes in RST in CLM. Impacts of RST temperatures on snow depth simulation could also be influenced by the patterns of temperature and precipitation, spatial resolution, and input terrain heights.

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.

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.

SIMULATION ON TEMPERATURE FIELD OF FRICTION STIR WELDED JOINTS OF 2024-T4 Al

The thermal model of FSW based on the thermal elastic-plastic finite element method, and the transient temperature distribution of FS welded joints of 2024-T4 Al was simulated by using this model, which provides useful information for the investigation of FSW process. Simulation resuits show that the temperature distribution of the weld gradually decreases toward periphery in a radiate format, whose center is the probe, and the highest temperature in the weld can reach about 400℃. The initial terminal of the weld is a zone, in which the temperature gradient is great, and defects of the welding are easily produced in this zone. Temperature change at the end of the welded joint is as layer variation, the local serious defects are not easy to produce in this zone.

Molecular Dynamics Simulations for Melting Temperatures of SrF2 and BaF2

The shell-model molecular dynamics method was applied to simulate the melting temper- atures of SrF2 and BaF2 at elevated temperatures and high pressures. The same method was used to calculate the equations of state for SrF2 and BaF2 over the pressure range of 0.1 MPa-3 GPa and 0.1 MPa-7 GPa. Compared with previous results for equations of state, the maximum errors are 0.3% and 2.2%, respectively. Considering the pre-melting in the fluorite-type crystals, we made the necessary corrections for the simulated melting temper- atures of SrF2 and BaF2. Consequently, the melting temperatures of SrF2 and BaF2 were obtained for high pressures. The melting temperatures of SrF2 and BaF2 that were obtained by the simulation are in good agreement with available experimental data.

Plant Temperature and Its Simulation Model of Thermo-Sensitive Genic Male Sterile Rice

Plant temperature （Tp） and its relations to the microclimate of rice colony and irrigation water were studied using a thermo-sensitive genic male sterile （TGMS） rice line, Pei＇ai 64S. Significant differences in the daily change of temperature were detected between Tp and air temperature at the height of 150 cm （TA）. From 8：00 to 20：00, Tp was lower than TA, but they were similar during 21：00 to next 7：00. The maximum Tp occurred one hour earlier than the maximum TA, though they both reached the minimum at 6：00. Tp fluctuated less than TA. At the same height, during 6：00-13：00, Tp was higher than air temperature （Ta）, and Tp reached the maximum one hour earlier than Ta. During the rest time on sunny day, Tp was close to or even a little lower than Ta. On overcast day, Tp was higher than Ta in the whole day, and both maximized at the same time. In addition, Tp was regulated by solar radiation, cloudage and wind speed in daytime, and by irrigation water at night. The present study indicated that a TA of 29.6℃ was the critical point, at which Tp was increased or decreased by irrigation water. Tp and the difference between water and air temperatures showed a conic relation. Tp fluctuation was also regulated by the absorption or reflection of solar radiation by leaves during daytime and release of heat energy during nighttime. By analysis on correlation and regression simulation, two models of Tp were established.

EXPERIMENTAL RESEARCH AND NUMERICAL SIMULATION OF MOLD TEMPERATURE FIELD IN CONTINUOUS CASTING OF STEEL

Mold is the heart of the continuous casting machine. Heat transfer and solidification in a water- cooled mold are the most important factors during the continuous casting of steel. For studying the temperature distribution of a mold wall, a simulated apparatus of mold was designed and experiments were performed by it. The measured results indicated that the mold wall temperature approaches the temperature of cooling-water. An equivalent thermal-conductivity coefficient was proposed and deduced on the basis of the conclusion of the experiments. This coefficient was applied to solve the heat transfer between the melt and cooling water, and to characterize the heat transfer capacity of the mold. By this equivalent thermal-conductivity coefficient, it is very easy and convenient to numerically simulate the solidification process of continuous casting. And the calculation results are in agreement with the experiments. The effects of custing speed and water flow rate on the mold temperature field were also discussed.

Numerical Simulation of High Temperature Air Combustion Flames Properties

High temperature air combustion (HTAC) is an attractive technology of saving energy and controlling environment. The mathematical models of turbulent jet flame under the highly preheated air combustion condition are conducted in the paper. The mixture fraction/probability density function model is employed. The results show that the maximum flame temperature is decreased, the temperature in the HTAC furnace is more uniform than that in the conventional furnace, and the NO x emission is low. The numerical results are partially validated by some experimental measurements.

Numerical simulation on temperature field for resistance spot welding of non-equal thickness stainless steel

An axisymmetric finite element model is developed to simulate the temperature field of resistant spot welding according to the process characters of nugget formation of non equal stainless steel sheets. A simulation method of the interaction of electrical and thermal factors is presented. The spot welding process of nugget formation is simulated using hard and soft welding technique norms. The heating characters of soft and hard norms determine the differences in the process of nugget formation and determine the finally shape and offset of nugget. Experimental verification shows that the model prediction agrees well with the practical.

A p-version embedded model for simulation of concrete temperature fields with cooling pipes

Pipe cooling is an effective method of mass concrete temperature control, but its accurate and convenient numerical simulation is still a cumbersome problem. An improved embedded model, considering the water temperature variation along the pipe, was proposed for simulating the temperature field of early-age concrete structures containing cooling pipes. The improved model was verified with an engineering example. Then, the p-version self-adaption algorithm for the improved embedded model was deduced, and the initial values and boundary conditions were examined. Comparison of some numerical samples shows that the proposed model can provide satisfying precision and a higher efficiency. The analysis efficiency can be doubled at the same precision, even for a large-scale element. The p-version algorithm can fit grids of different sizes for the temperature field simulation. The convenience of the proposed algorithm lies in the possibility of locating more pipe segments in one element without the need of so regular a shape as in the explicit model.