Quasi-direct numerical simulations of the flow characteristics of a thermal plasma reactor with counterflow jet

Three-dimensional quasi-direct numerical simulations have been performed to investigate a thermal plasma reactor with a counterflow jet. The effects of the momentum flux ratio and distance between the counterflow jet and the thermal plasma jet on the flow characteristics are addressed. The numerical results show that the dimensionless location of the stagnation layer is significantly affected by the momentum flux ratio, but it is not dependent on the distance.Specifically, the stagnation layer is closer to the plasma torch outlet with the increase of the momentum flux ratio. Furthermore, the flow regimes of the stagnation layer and the flow characteristics of the thermal plasma jet are closely related to the momentum flux ratio. The characteristic frequencies associated with the different regimes are identified. The deflecting oscillation flow regimes are found when the momentum flux ratio is low, which provokes axial velocity fluctuations inside the thermal plasma jet. By contrast, for cases with a high momentum flux ratio, flapping flow regimes are distinguished. The thermal plasma jets are very stable and the axial velocity fluctuations mainly exist in the stagnation layer.

Operation optimization of prefabricated light modular radiant heating system:Thermal resistance analysis and numerical study

The utilization of prefabricated light modular radiant heating system has demonstrated significant increases in heat transfer efficiency and energy conservation capabilities.Within prefabricated building construction,this new heating method presents an opportunity for the development of comprehensive facilities.The parameters for evaluating the effectiveness of such a system are the upper surface layer’s heat flux and temperature.In this paper,thermal resistance analysis calculation based on a simplified model for this unique radiant heating system analysis is presented with the heat transfer mechanism’s evaluation.The results obtained from thermal resistance analysis calculation and numerical simulation indicate that the thermal resistance analysis method is highly accurate with temperature discrepancies ranging from 0.44℃ to−0.44℃ and a heat flux discrepancy of less than 7.54%,which can meet the requirements of practical engineering applications,suggesting a foundation for the prefabricated radiant heating system.

Numerical Investigation of Thermal Behavior of CNC Machine Tool and Its Effects on Dimensional Accuracy of Machined Parts

The dimensional accuracy of machined parts is strongly influenced by the thermal behavior of machine tools (MT). Minimizing this influence represents a key objective for any modern manufacturing industry. Thermally induced positioning error compensation remains the most effective and practical method in this context. However, the efficiency of the compensation process depends on the quality of the model used to predict the thermal errors. The model should consistently reflect the relationships between temperature distribution in the MT structure and thermally induced positioning errors. A judicious choice of the number and location of temperature sensitive points to represent heat distribution is a key factor for robust thermal error modeling. Therefore, in this paper, the temperature sensitive points are selected following a structured thermomechanical analysis carried out to evaluate the effects of various temperature gradients on MT structure deformation intensity. The MT thermal behavior is first modeled using finite element method and validated by various experimentally measured temperature fields using temperature sensors and thermal imaging. MT Thermal behavior validation shows a maximum error of less than 10% when comparing the numerical estimations with the experimental results even under changing operation conditions. The numerical model is used through several series of simulations carried out using varied working condition to explore possible relationships between temperature distribution and thermal deformation characteristics to select the most appropriate temperature sensitive points that will be considered for building an empirical prediction model for thermal errors as function of MT thermal state. Validation tests achieved using an artificial neural network based simplified model confirmed the efficiency of the proposed temperature sensitive points allowing the prediction of the thermally induced errors with an accuracy greater than 90%.

Numerical Simulation on Thermal Stress of Large-scale Bearing Roller during Heating Process of Final Heat Treatment

hi this paper, the non-linear finite element method had been applied to calculate the thermal stress evolving process of the large-scale bearing roller during heating process of final heat treatment. It was found that two stress peaks appeared during heating process and the second stress peak was higher than the first. If the preheating time was elongated, the second stress peak was reduced distinctly. Therefore, the pre-heating time should be elongated suitably to ensure safety in the practical manufacture process.

Numerical Simulation of Transient Thermal Stress Field for Laser Metal Deposition Shaping

To decrease thermal stress during laser metal deposition shaping(LMDS)process,it is of great importance to learn the transient thermal stress distribution regularities.Based on the“element life and death”technique of finite element analy- sis(FEA),a three-dimensional multi-track and multi-layer numerical simulation model for LMDS is developed with ANSYS parametric design language(APDL)for the first time,in which long-edge parallel reciprocating scanning paths is introduced. Through the model,detailed simulations of thermal stress during whole metal cladding process are conducted,the generation and distribution regularities of thermal stress are also discussed in detail.Using the same process parameters,the simulation results show good agreement with the features of samples which fabricated by LMDS.

Numerical Simulation of Methane Distribution and Sensor Placement in 2-Dimension Roadway

In order to provide a theoretical basis for methane sensor placement in the vertical direction of a tunnel,the software Fluent was used to simulate methane distribution. A geometric roadway model was established and divided by grids. Methane distribution in both level and vertical sections was simulated using a realizable k-ε model with the Fluent software according to a conservation equation in a turbulent state,a turbulent kinetic energy equation and a turbulent dissipation rate equation. The realizable k-ε model and the Fluent software were used to simulate methane distribution according to the principle of the conservation equation in a state of turbulent flow. The results show that after overflow-ing,a methane level with a certain thickness is formed. Methane density curves at three specific levels were internally consistent and methane density at higher levels is denser than that at lower levels. Methane distribution becomes thinner in the direction of wind and methane in the vertical direction becomes uniform if wind speed is high. The distance be-tween sensors and roof should be less than 300 mm which is in agreement with mine safety regulations.

Numerical simulation of dynamic thermal process during doublesided asymmetrical TIG backing welding of large thick plates

The dynamic thermal process during double-sided asymmetrical TIG backing welding of large thick plates （ 1 000 mm×700 mm×50 mm） is numerically simulated using MSC. MARC. The effect of arc distance on the thermal cycle in weld zone during double-sided asymmetrical T1G backing welding is investigated. The results show that the workpiece experiences double-peak thermal cycle in double-sided asymmetrical TIG backing welding. On the one hand, the fore arc has the pre- heating effect on the rear pass, and the pre-heating temperature depends on the distance between the double arcs, the heat input of fore arc, and the initial temperature of workpiece. On the other hand, the rear arc has the post-heating effect on the fore pass. The mutual effects of two heat sources decrease with the increase of arc distance.

Numerical Simulation of Thermal Stress Fields in the Magnetic Quenching Process of 45 Steel

Based on a transient temperature distribution of a 45 steel cylinder workpiece during magnetic quenching, which was obtainedby solving the governing equations with nonlinear boundary on the condition of coupling effects of heat-magnetism. Accordingto the theory of thermal non-elasticity, computational mechanics, ferromagnetism and phase transformation, a new constitutiveequation considering effects of phase transformation is proposed and solved by means of finite element method. The transientthermal stress and residual stress are obtained and the influencing factors on the thermal stress of magnetic field are analyzedand discussed.

Review of Numerical Simulation of TGO Growth in Thermal Barrier Coatings

Thermally grown oxide(TGO)is a critical factor for the service life of thermal barrier coatings(TBC).Numerical simulations of the growth process of TGO have become an effective means of comprehensively understanding the progressive damage of the TBC system.At present,technologies of numerical simulation to TGO growth include two categories:coupled chemical-mechanical methods and mechanical equivalent methods.The former is based on the diffusion analysis of oxidizing elements,which can describe the influence of bond coat(BC)consumption and phase transformation in the growth process of TGO on the mechanical behavior of each layer of TBC,and has high accuracy for the thickness evolution of TGO,but they cannot describe the lateral growth of TGO and the rumpling phenomenon induced.The latter focuses on describing the final stress and strain state after the growth of a specific TGO rather than the complete growth processes of TGO.Based on the measured TGO thickness growth curve,simulations of thickening and lateral growth can be achieved by directly applying anisotropic volumetric strain to oxidized elements and switching elements properties from the BC to the TGO.

Numerical simulation of thermal process and energy saving of lime furnace

Based on the principle of thermal balance and material balance of lime furnace, the reaction and heat transfer process mathematical-physical model and the on-line monitoring model of the decomposition rate of limestone were set up. With this model, numerical simulation is used to analyze the effects of operational parameters on the process of lime calcining and to optimize it. By using visual basic program to communicate and program, the centralized management and automatic control of the lime furnace are realized. The software is put into practical production, which makes the lime furnace operate steadily and efficiently, and causes the increase in output and decrease in energy consumption.

Numerical simulation of thermal behavior during laser metal deposition shaping

Abstract: Based on the element life and death theory of finite element analysis(FEA), a three-dimensional multi-track and multi-layer model for laser metal deposition shaping(LMDS) was developed with ANSYS parametric design language(APDL), and detailed numerical simulations of temperature and thermal stress were conducted. Among those simulations, long-edge parallel reciprocating scanning method was introduced. The distribution regularities of temperature, temperature gradient, Von Mise’s effective stress, X-directional, Y-directional and Z-directional thermal stresses were studied. LMDS experiments were carried out with nickel-based superalloy using the same process parameters as those in simulation. The measured temperatures of molten pool are in accordance with the simulated results. The crack engendering and developing regularities of samples show good agreement with the simulation results.

Numerical Simulation of Vacuum Heat Treatment Thermal Hysteresis Time of GH4169 Superalloy Workpiece

A nonlinear finite element model of vacuum heat treatment process was developed. In this model, influence of many factors, such as nonlinear heat radiation, temperature-dependent thermal physical properties of material are considered. The temperature field of GH4169 alloy workpiece during vacuum heat treatment process was calculated using finite element software MSC.Marc, and the thermal hysteresis time of the workpiece was predicted. An experiment of vacuum heat treatment of GH4169 superalloy workpiece was carried out to verify the calculation. The experimental results of temperature profile agree well with the simulated results. This work lays a theoretical foundation for optimizing technical parameter of vacuum heat treatment process.

Techniques for improving computational speed in numerical simulation of casting thermal stress based on finite difference method

Finite difference method (FDM) was applied to simulate thermal stress recently, which normally needs a long computational time and big computer storage. This study presents two techniques for improving computational speed in numerical simulation of casting thermal stress based on FDM, one for handling of nonconstant material properties and the other for dealing with the various coefficients in discretization equations. The use of the two techniques has been discussed and an application in wave-guide casting is given. The results show that the computational speed is almost tripled and the computer storage needed is reduced nearly half compared with those of the original method without the new technologies. The stress results for the casting domain obtained by both methods that set the temperature steps to 0.1 ℃ and 10 ℃, respectively are nearly the same and in good agreement with actual casting situation. It can be concluded that both handling the material properties as an assumption of stepwise profile and eliminating the repeated calculation are reliable and effective to improve computational speed, and applicable in heat transfer and fluid flow simulation.

STUDY ON NUMERICAL SIMULATION OF CASTING THERMAL STRESSES BASED ON FDM

A system for the numerical simulation of 3D temperature and stress fields during casting process was studied, developed and practiced based on finite difference method (FDM) in this paper. An approach where the stress/strain and the heat transfer analysis use the same computational domain was presented, which avoided transferring temperature data between FDM and FEM nodes and elements. A slot-board steel casting was simulated and the calculated results are in agreements with those obtained from practical producing.

NUMERICAL SIMULATION OF TRANSIENT THERMAL FIELD IN LASER MELTING PROCESS

Numerical simulation of thermal field was studied in laser processing. The 3-D finite element model of transient thermal calculation is given by thermal conductive equation. The effects of phase transformation latent are considered. Numerical example is given to verify the model. Finally the real example of transient thermal field is given.

Study on the Thermal internal Boundary Layer and Dispersion of Air Pollutant in Coastal Area by Numerical Simulation

In this paper, a scheme on a mesoscale dispersion modeling system was set up. The modeling system was used tostudy the turbulence structure of TIBL and dispersion features under shoreline tlimigation situation. The modelingsystem has successfully solved the problem of meteorological input of stochastic dispersion models and exploited anew approach to comprehensive application of this kind of dispersion models.

Numerical Simulation of a Courtyard under Different Ground Thermal Conditions and Flow Patterns

The impact of thermal conditions of the ground on ventilation in the interior courtyard and rooms of enclosed building is very important to improve the air quality in courtyard. The computational fluid dynamics( CFD) model was used to investigate the flow field of a certain courtyard and analyze the static differential pressure between the two sides of the vent and ventilation conditions of the courtyard. The results indicate that thermal effects not only changed the air flow pattern of the interior courtyard but also obviously increased the flow velocity of the upper space of the courtyard. For the most of courtyard rooms,the absolute value of static differential pressure increases as the thermal intensity of the ground increases. In all wind directions,the air exchange rate of the courtyard increases with the higher thermal intensity of the ground which makes a greater influence on the increasing of the ventilation rate of the roof opening than that on the gate opening.

Numerical Simulation of Thermal Discharge Based on FVM Method

A two-dimensional numerical model is proposed to simulate the thermal discharge from a power plant in Jiangsu Province. The equations in the model consist of two-dimensional non-steady shallow water equations and thermal waste transport equations. Finite volume method （FVM） is used to discretize the shallow water equations, and flux difference splitting （FDS） scheme is applied. The calculated area with the same temperature increment shows the effect of thermal discharge on sea water. A comparison between simulated results and the experimental data shows good agreement. It indicates that this method can give high precision in the heat transfer simulation in coastal areas.