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.

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]

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.

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.

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.

Temperature field simulation of laser-TIG hybrid welding

The three dimensional transient temperature distribution of laser TIG hybrid welding was analyzed and simulated numerically. Calculations were based on a finite element model, in which the physical process of hybrid welding was studied and the coupling effect of the laser and arc in the hybrid process was fully considered. The temperature fields and weld cross sections of the typical welding parameters are obtained using present model. The calculation results show that the model can indicate the relationship of energy match between laser and arc to joints cross sections objectively, and the simulation results are well agreed with the experimental results.

NUMERICAL SIMULATION OF TEMPERATURE FIELDS FOR WELD METAL SOLIDIFICATION CRACKING IN STAINLESS STEELS

This paper has analyzed the influences of the heat input of welding arc, the latent heat of solidifica- tion,fluid flow of liquid metal on the heat conductivity pertaining to welding solidification crack of stainless steels. As a result,two - dimensional heat conduction models with prescribed heat flux mov- ing along the the have been developed that can simulate welding arc, convection and radiation heat loss from top and bottom surfaces of the workpiece. Finally, the finite element model was used to ana- lyze and calculate the temperature field.

Numerical simulation of wellbore and formation temperature fields in carbonate formations during drilling and shut-in in the presence of lost circulation

Temperature curves reflect geothermal gradients and local temperature anomalies, thus providing a new understanding of the underground reservoir conditions. When encountering caverns or fractures and fissures during drilling, lost circulation may occur and result in a change to the original formation temperature field, and in severe cases, even the conventional open hole well logging data cannot be obtained. This paper uses finite element analysis software COMSOL to establish a heat transfer model for the wellbore/reservoir formation system during drilling and shut-in in the presence of lost circulation, and a case study is made in a carbonate reservoir in the Tahe oilfield. On the basis of the above, we analyze the temperature distribution in the leakage zone, and the studies have shown that the leakage and petrophysical properties have an impact on the temperature of the wellbore and formation, hence we can estimate the reservoir permeability using the temperature data. In addition, the determination of the temperature recovery time after some drilling fluids have leaked into the formation will help in recognizing the subsurface temperature field of the carbonate formation correctly, thus enhancing production logging interpretation accuracy and improving the understanding of later measurements.

Numerical simulation of gas metal arc welding temperature field

The infrared camera is used to investigate the temperature field of gas metal arc welding. The results show that the temperature distribution of weld pool and adjacent area appears cone shape. A new heat source model combined by Gaussian distribution heat source of the arc and conical distribution heat source of the droplet is set up based on the experimental results, and with the combined boundary conditions, the temperature field of gas metal arc welding is simulated using finite element method. According to the comparison between the results of experiment and simulation in temperature field shows that the new combined heat source model is more accurate and effective than the Gauss heat source model.

Numerical simulation of the temperature field within new type of monolayer freezing-shaft lining

Numerical simulation was used to estimate the temperature field within a poured concrete,mono-layer freezing-shaft lining.The affects from various factors were investigated.The maximum temperature within the lining increases as the lining thickness increases,decreases as the soil-side wall temperature decreases,decreases as the air temperature inside the shaft decreases and decreases as the air velocity inside the shaft increases.The compression speed of an insulating foam layer affects the maximum temperature difference between the interior and the sidewalls.The maximum temperature difference between the interior and the sidewalls approaches or exceeds the maximum allowable for the curing of poured concrete structures.Attention should be paid to the question of the lining cracking during the curing period.The temperature gradient in the vertical direction may be minimized by preventing air contact against the steel connection board supporting the base of the freshly poured section.

Frictional heat analysis of mine hoist and numerical simulation on temperature field of gasket

The frictional performance of gaskets is greatly affected by frictional heat in operational mine hoists. Based on frictional mechanism and heat transfer theory, the mathematical model of the temperature field of the PVC gasket in an operational mine hoist was investigated, a numerical simulation using ANSYS is presented and the distribution of the temperature and heat flux were studied under basic assumptions. The results show that the temperature gradually decreases as the radius of the model increases and the isotherms are arcs of concentric semi-circle. The heat flux is of bilateral symmetry in the model and decreases radially. The theoretical values correspond with the measured values for a short time (τ≤ 100 s) when the steel wire rope slides.

Numerical simulation of the temperature field of titania-bearing BF slag heated in a microwave oven

Considering the characteristic of selective heating of microwave and the treatment of titania-bearing BF slag, a mathematical model for the heating of a slag specimen is developed. The temperature distribution in the specimen is studied by numerical simulation. The temperature in the center of the cylindrical slag specimen is the highest and the temperature decreases when the radius increases rapidly. In this case, the temperature rising rate decreases with heating time rapidly, and it tends to zero when the heating time is up to 150 s.

NUMERICAL SIMULATION OF TEMPERATURE FIELD ON FLASH BUTT WELDING FOR HIGH MANGANESE STEELS

An axial symmetry finite element model coupled with electricity-thermal effect was developed to study the temperature field distribution in process of the flash butt welding （FBW） of frog highmanganese steel. The influence of temperature dependent material properties and the contact resistance were taken into account in FEM ＇simulation. Meanwhile, the lost materials due to .splutter was resolved by using birth and death element. The result of analyzing data shows that the moddel in the FBW flashing is reasonable and feasible, and can exactly simulate the temperature field distribution. The modeling provides reference for analysis of welding technologies on the temperature field of high-manganese steel in FBW.

Numerical simulation of temperature fields for weld metal solidification cracking in stainless steels

This paper has analyzed the influences of the heat input of the welding arc, the latent heat of solidification, the fluid flow of liquid metal on the heat conductivity pertaining to the welding solidification crack of stainless steels. As a result, two dimensional heat conduction models with the prescribed heat flux moving along the weld have been developed that can simulate welding arc, convection and radiation heat loss from top and bottom surfaces of the workpiece. Finally, the finite element model was used to analyze and calculate the temperature fields.

The influence of the initial temperature field on sea ice simulations in the Bohai Sea in winter of 2015/2016

To assess the influence of the initial temperature field on ocean temperature and sea ice simulations,a climatological dataset(WOA18),a real-time varying dataset(SODA),and an analysis field obtained after applying the“vertical projection”assimilation scheme were selected to obtain the initial temperature field(the initial moment was December 1,2015)for use in the sea ice simulation of the HAMSOM ice-ocean coupled model,considering the Bohai Sea in the 2015/2016 winter.In this study,after using this assimilation scheme,the analysis initial temperature field showed significant improvement.The simulated SST results showed that the initial temperature field had a considerable effect on the SST results in the first 45 days of the model run;after this period,the effect became negligible and the model internal dynamics and atmospheric forcing became dominant.The simulated sea ice results showed that the ice area and ice edge distance(i.e.,the distance between the intersection of the central axis and the ice edge line and axis apex)results obtained in experiment E3 which used the analysis initial temperature field were improved by~14%and~35%,respectively,and those obtained in experiment E2 which used the real-time varying initial temperature field were improved by~10%and~22%,respectively,compared to the results of experiment E1 which used the climatological initial temperature field.

Numerical Simulation of the Temperature Field in Sintering of TiB_2-BN by SPS

The temperature field during the whole process of SPS sintering TiB2 -BN sample was numerically simulated based on the simplification of the temperature rising process. The result shows that the highest temperature is found in the punch and the heat flows from punch to sample and die in SPS sintering system. In the radial direction, the center temperature of the sample is much higher than the circumference temperature of the sampie. In the axial direction, the center temperature of the sample is lower than the border temperature of the sampie. The temperature difference in the sample is growing bigger in the sintering process and reaches the maximum at the end of the heating-up process.

NUMERICAL SIMULATION OF TEMPERATURE FIELD FOR COAT OF COAT-CAST TECHNOLOGY

Using Fourier's conduction equation, a mathematical model of the temperature field for the coat of coat-cast technology is established. The relationship between the thickness, quality of the coat and casting temperature of liquid iron is analyzed. The results show that the coat quality is reliable; the combination of the coat with the base is solid; because foe temperature gradient of the coat is not large, the surface, middle and bond area of the coat are melted completely and the thickness of the coat can reach 2.3mm by using self-melting spraying alloy powder when the casting temperature is higher than 1380℃. In addition, the agreement between the calculated and measured values is good. This paper is of significant meaning for coat-cast technology and the coat quality.

Numerical simulation of the temperature field of twin-roll thin strip continuous casting

In this study, the temperature field model of twin-roll thin strip continuous casting was developed, and the interface heat transfer coefficient between the air and the strip surface was computed by using the inverse method. The effects of the process parameters including the casting speed, liquid level height, pouring temperature and thickness of the thin strip on the outlet temperature of the rotating rolls and the surface temperature of the thin strip were analyzed.

Numerical Simulation of Temperature Field of Die Casting Dies

In this study, the Solidworks was used as pre-processor, which performed the three- dimensional solid construction and automatic enmeshment. The COSMOS was adopted as post- processor to display the temperature distribution and further to simulate the thermal stress distribution of dies. A software package for three-dimensional temperature fields of complicated die casting and its dies was developed and the temperature distributions of a fan cover casting were simulated by the software.