展向具有谐波型扰动的方柱旋涡分离流数值研究

基于Fourier谱方法和有限差分的混合方法，对方型截面柱体的分离流及非定常涡动力学进行数值研究，特别是展向具有谐波型几何扰动对流动演化及受力变化的影响。结果表明，当Re=100-150，在未引入扰动的柱体上／下表面处（而非前缘）流动发生局部分离，并形成分离泡。流动分离点随Re数增加是逐渐从后缘前移到前缘附近。沿展向引入扰动后，当Re=100时，在柱体表面产生流向与垂向涡量，甚至抑制了展向涡的发展。当波陡度（波高／波长）为0．167时，产生了类似于发夹涡的结构，此时柱体平均阻力系数和升力系数幅值分别减小了9％和98％。并讨论了相关的机制。

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.

Case study on the mechanics of NPR anchor cable compensation for large deformation tunnel in soft rock in the Transverse Mountain area,China

A study was conducted to analyze the deformation mechanism of strongly weathered quartz schist in the Daliangshan Tunnel,located in the western Transverse Mountain area.A large deformation problem was experienced during the tunnel construction.To mitigate this problem,a support system was designed incorporating negative Poisson ratio(NPR)anchor cables with negative Poisson ratio effect.Physical model experiments,field experiments,and numerical simulation experiments were conducted to investigate the compensation mechanical behavior of NPR anchor cables.The large deformations of soft rocks in the Daliangshan Tunnel are caused by a high ground stress,a high degree of joint fracture development,and a high degree of surrounding rock fragmentation.A compensation mechanics support system combining long and short NPR anchor cables was suggested to provide sufficient counter-support force(approximately 350 kN)for the surrounding rock inside the tunnel.Comparing the NPR anchor cable support system with the original support system used in the Daliangshan tunnel showed that an NPR anchor cable support system,combining cables of 6.3 m and 10.3 m in length,effectively prevented convergence of surrounding rock deformation,and the integrated settlement convergence value remained below 300 mm.This study provides an effective scientific basis for resolving large deformation problems in deeply buried soft rocks in western transverse mountain areas.

A Hybrid Dung Beetle Optimization Algorithm with Simulated Annealing for the Numerical Modeling of Asymmetric Wave Equations

In the generalized continuum mechanics(GCM)theory framework,asymmetric wave equations encompass the characteristic scale parameters of the medium,accounting for microstructure interactions.This study integrates two theoretical branches of the GCM,the modified couple stress theory(M-CST)and the one-parameter second-strain-gradient theory,to form a novel asymmetric wave equation in a unified framework.Numerical modeling of the asymmetric wave equation in a unified framework accurately describes subsurface structures with vital implications for subsequent seismic wave inversion and imaging endeavors.However,employing finite-difference(FD)methods for numerical modeling may introduce numerical dispersion,adversely affecting the accuracy of numerical modeling.The design of an optimal FD operator is crucial for enhancing the accuracy of numerical modeling and emphasizing the scale effects.Therefore,this study devises a hybrid scheme called the dung beetle optimization(DBO)algorithm with a simulated annealing(SA)algorithm,denoted as the SA-based hybrid DBO(SDBO)algorithm.An FD operator optimization method under the SDBO algorithm was developed and applied to the numerical modeling of asymmetric wave equations in a unified framework.Integrating the DBO and SA algorithms mitigates the risk of convergence to a local extreme.The numerical dispersion outcomes underscore that the proposed SDBO algorithm yields FD operators with precision errors constrained to 0.5‱while encompassing a broader spectrum coverage.This result confirms the efficacy of the SDBO algorithm.Ultimately,the numerical modeling results demonstrate that the new FD method based on the SDBO algorithm effectively suppresses numerical dispersion and enhances the accuracy of elastic wave numerical modeling,thereby accentuating scale effects.This result is significant for extracting wavefield perturbations induced by complex microstructures in the medium and the analysis of scale effects.

Optimization of Channel Structure of Alkaline Water Electrolyzer by Using an Expanded Mesh as a Bipolar Plate

Alkaline water electrolysis(AWE)is the most mature technology for hydrogen production by water electrolysis.Alkaline water electrolyzer consists of multiple electrolysis cells,and a single cell consists of a diaphragm,electrodes,bipolar plates and end plates,etc.The existing industrial bipolar plate channel is concave-convex structure,which is manufactured by complicated and high-cost mold punching.This structure still results in uneven electrolyte flow and low current density in the electrolytic cell,further increasing in energy consumption and cost of AWE.Thereby,in this article,the electrochemical and flow model is firstly constructed,based on the existing industrial concave and convex flow channel structure of bipolar plate,to study the current density,electrolyte flow and bubble distribution in the electrolysis cell.The reliability of the model was verified by comparison with experimental data in literature.Among which,the electrochemical current density affects the bubble yield,on the other hand,the generated bubbles cover the electrode surface,affecting the active specific surface area and ohmic resistance,which in turn affects the electrochemical reaction.The result indicates that the flow velocity near the bottom of the concave ball approaches zero,while the flow velocity on the convex ball surface is significantly higher.Additionally,vortices are observed within the flow channel structure,leading to an uneven distribution of electrolyte.Next,modelling is used to optimize the bipolar plate structure of AWE by simulating the electrochemistry and fluid flow performances of four kinds of structures,namely,concave and convex,rhombus,wedge and expanded mesh,in the bipolar plate of alkaline water electrolyzer.The results show that the expanded mesh channel structure has the largest current density of 3330 A/m^(2)and electrolyte flow velocity of 0.507 m/s in the electrolytic cell.Under the same current density,the electrolytic cell with the expanded mesh runner structure has the smallest potential and energy consumption.This work provides a useful guide for the comprehensive understanding and optimization of channel structures,and a theoretical basis for the design of large-scale electrolyzer.

Determination of wax pattern die profile for investment casting of turbine blades

In order to conform to dimensional tolerances, an efficient numerical method, displacement iterative compensation method, based on finite element methodology （FEM） was presented for the wax pattern die profile design of turbine blades. Casting shrinkages at different positions of the blade which was considered nonlinear thermo-mechanical casting deformations were calculated. Based on the displacement iterative compensation method proposed, the optimized wax pattern die profile can be established. For a A356 alloy blade, substantial reduction in dimensional and shape tolerances was achieved with the developed die shape optimization system. Numerical simulation result obtained by the proposed method shows a good agreement with the result measured experimentally. After four times iterations, compared with the CAD model of turbine blade, the total form error decreases to 0.001 978 mm from the orevious 0.515 815 mm.

Forming defects in aluminum alloy hot stamping of side-door impact beam

The forming defects, including thinning, rupture, wrinkling and springback, usually arising in producing a side-door impact beam, were investigated by trial and numerical simulation. A temperature-related constitutive model specific to the temperature range from 350 °C to 500 °C was established and used for the numerical simulation. The trial and numerical simulation were conducted to clarify the quantitative characteristics of forming defects and to analyze the effects of process parameters on the forming defects. Results show that the rupture situation is ameliorated and the springback is eliminated in the aluminum alloy hot stamping. The wrinkling severity decreases with increasing blank holder force (BHF), but the BHF greater than 15 kN causes the rupture at the deepest drawing position of workpiece. The forming defects are avoided with lubricant in the feasible ranges of process parameters: the BHF of 3 to 5 kN and the stamping speed of 50 to 200 mm/s.

Numerical simulation of intermediate phase growth in Ti/Al alternate foils

To investigate the diffusion reaction between Ti/Al solid diffusion couple, Ti/Al alternate foils formed by hot pressing were annealed at 525, 550, 575 and 600 °C for time ranging from 1 to 40 h. The experimental results show that TiAl3 was the only observed phase at Ti/Al interface. The interface thermodynamics favored the preferential formation of TiAl3 in Ti/Al couple. The growth of TiAl3 layer occurred mainly towards Al foil side and exhibited a parabolic law. Using the interdiffusion coefficients calculated based on the contribution of grain boundary diffusion, the growth of TiAl3 was simulated numerically with the finite difference method, and the simulated results were in good agreement with the experimental ones.

Numerical simulation of LWD resistivity response of carbonate formation using self-adaptive hp-FEM

Most of the carbonate formation are highly heterogeneous with cavities of different sizes, which makes the prediction of cavity-filled reservoir in carbonate rocks difficult. Large cavities in carbonate formations pose serious threat to drilling operations. Logging-whiledrilling （LWD） is currently used to accurately identify and evaluate cavities in reservoirs during drilling. In this study, we use the self-adaptive hp-FEM algorithm simulate and calculate the LWD resistivity responses of fracture-cavity reservoir cavities. Compared with the traditional h-FEM method, the self-adaptive hp-FEM algorithm has the characteristics of the self-adaptive mesh refinement and the calculations exponentially converge to highly accurate solutions. Using numerical simulations, we investigated the effect of the cavity size, distance between cavity and borehole, and transmitted frequency on the LWD resistivity response. Based on the results, a method for recognizing cavities is proposed. This research can provide the theoretical basis for the accurate identification and quantitative evaluation of various carbonate reservoirs with cavities encountered in practice.

Forced convection rheoforming process for preparation of 7075 aluminum alloy semisolid slurry and its numerical simulation

A self-developed forced convection rheoforming （FCR） machine for the preparation of light alloy semisolid slurry was introduced. The microstructure characteristics of 7075 aluminium alloy semisolid slurry at different stirring speeds prepared by the FCR process were analyzed. The experimental results suggest that with the increase of the stirring speed, the mean grain size of the semisolid decreases and the shape factor as well as the number of primary grains increase. Meanwhile, the preparation process of semisolid slurry was numerically simulated. The flow characteristics of the melt in the device and the effect of the stirring speed on temperature field and solid fraction of the melt were investigated. The simulated results show that during the preparation process of semisolid slurry, there is a complex convection within the FCR device that obviously changes the temperature field distribution and solid fraction of the melt. When the convection intensity increases, the scope of the undercooling gradient of the melt is reduced and temperature distribution is improved.

Numerical simulation of acoustic pressure field for ultrasonic grain refinement of AZ80 magnesium alloy

Ultrasound with different intensities was applied to treating AZ80 alloy melt to improve its solidification structure.The average grain size of the alloy could be decreased from 303 to 148 μm after the ultrasound with intensity of 30.48 W/cm2 was applied.To gain insight into the mechanism of ultrasonic treatment which affected the microstructure of the alloy,numerical simulations were carried out and the effects of different ultrasonic pressures on the behaviors of cavitation bubble in the melt were studied.The ultrasonic field propagation in the melt was also characterized.The results show that samples from different positions are subjected to different acoustic pressures and the effect of grain refinement by ultrasonic treatment for these samples is different.With the increase of ultrasonic intensity,the acoustic pressure is increased and the grain size is decreased generally.

Visualization and simulation of plastic material flow in friction stir welding of 2024 aluminium alloy plates

Thin copper sheets as marker material were embedded into weld path of 2024 aluminium alloy plates and their final position after friction stir welding was examined by metallographic techniques. Referring to the visualized material flow patterns, a three-dimensional model was developed to conduct the numerical simulation of the temperature profile and plastic material flow in friction stir welding. The calculated velocity contour of plastic flow in close proximity of the tool is generally consistent with the visualized results. As the tool rotation speed increases at a constant tool travel speed, the material flow near the pin gets stronger. The predicted shape and size of the weld nugget zone match with the experimentally measured ones.

CFD numerical simulation of flow velocity characteristics of hydrocyclone

A CFD based numerical simulation of flow velocity of hydrocyclone was conducted with different structural and operational parameters to investigate its distribution characteristics and influencing mechanism. The results show there exist several unsymmetrical envelopes of equal vertical velocities in both upward inner flows and downward outer flows in the hydrocyclone, and the cone angle and apex diameter have remarkable influence on the vertical location of the cone bottom of the envelope of zero vertical velocity. It is also found that the tangential velocity isolines exist in the horizontal planes located in the effective separation region of hydrocyclone. The increase of feed pressure has almost no effect on the distribution characteristics of both vertical velocity and tangential velocity in hydrocyclone, but the magnitude and gradient of tangential velocity are increased obviously to make the motion velocity of high density particles to the wall increased and to make the cyclonic separation effect improved.

Inhomogeneity of density and mechanical properties of A357 aluminum alloy backward extruded in semi-solid state

The inhomogeneity of density and mechanical properties of A357 aluminum alloy in the semi-solid state were investigated.Numerical simulation and backward extrusion were adopted to study the preparation of cup shells.The results show that the relative density of the wall is the lowest in samples,and that of the base is the highest.With increasing the billet height,more time is needed for relative density of the corner to reach the maximum value,and the relative densities in every region improve evidently with increasing the pressure.The tensile stress was simulated to be the largest at the corner,and the hot tearings were forecasted to mainly appear at the corner too.By employing proper billet height and pressure,the extruded samples consisted of fine and uniform microstructures,and can obtain excellent mechanical properties and Brinell hardness.

Analysis and application of the response characteristics of DLL and LWD resistivity in horizontal well

There exist different response characteristics in the resistivity measurements of dual laterolog （DLL） and logging while drilling （LWD） electromagnetic wave propagation logging in highly deviated and horizontal wells due to the difference in their measuring principles. In this study, we first use the integral equation method simulated the response characteristics of LWD resistivity and use the three dimensional finite element method （3D-FEM） simulated the response characteristics of DLL resistivity in horizontal wells, and then analyzed the response differences between the DLL and LWD resistivity. The comparative analysis indicated that the response differences may be caused by different factors such as differences in the angle of instrument inclination, anisotropy, formation interface, and mud intrusion. In the interface, the curves of the LWD resistivity become sharp with increases in the deviation while those of the DLL resistivity gradually become smooth. Both curves are affected by the anisotropy although the effect on DLL resistivity is lower than the LWD resistivity. These differences aid in providing a reasonable explanation in the horizontal well. However, this can also simultaneously lead to false results. At the end of the study, we explain the effects of the differences in the interpretation of the horizontal well based on the results and actual data analysis.

Furnace structure analysis for copper flash continuous smelting based on numerical simulation

According to the innate characteristic of four types of furnace, the copper flash continuous smelting （CFCS） furnace can be considered a synthetic reactor of two relatively independent processes： flash matte smelting process （FMSP） and copper continuous converting process （CCCP）. Then, the CFCS thermodynamic model was proposed by establishing the multi-phase equilibrium model of FMSP and the local-equilibrium model of CCCP, respectively, and by combining them through the smelting intermediates. Subsequently, the influences of the furnace structures were investigated using the model on the formation of blister copper, the Fe3O4 behavior, the copper loss in slag and the copper recovery rate. The results show that the type D furnace, with double flues and a slag partition wall, is an ideal CFCS reactor compared with the other three types furnaces. For CFCS, it is effective to design a partition wall in the furnace to make FMSP and CCCP perform in two relatively independent zones, respectively, and to make smelting gas and converting gas discharge from respective flues.

Numerical simulation and physical analysis for dynamic behaviors of P/M TiAl alloy in hot-packed forging process

The hot forging of large-scale P/M TiAl alloy billet deformation was investigated based on a joint application of Deform-3D-based numerical simulation and physical simulation techniques.The temperature dependence on the thermal and mechanical properties of the billet was considered and the optimum hot working temperature of packed TiAl alloy was 1150-1200 °C.Based on the simulation,the material flow and thermo mechanical field variables,such as stress,strain,and temperature distribution were obtained and the relationships of load—displacement and load—time were figured out.To verify the validity of the simulation results,the experiments were also carried out in a forging plant,and a pancake with diameter of 150 mm was obtained exhibiting a regular shape.

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]

Migration behavior of solidification nuclei in pure Al melt under effect of electric current pulse

A mathematical model considering free nuclei was developed to reveal the migration behavior of the free nuclei. Numerical simulation results show that most of the nuclei on the top surface of the melt move downwards and distribute randomly inside the Al melt, which induces more nucleation sites resulting in grain refinement. At the same time, the effect of nuclei size on the nuclei distribution and refinement employing electric current pulse （ECP） was also investigated. The smaller nuclei migrate a short distance with the Al melt at lower speed. But for the larger nuclei, the migration downwards with higher speed benefits the refinement of interior grains of the melt. The research results help to better understand the refinement process and provide a more reasonable explanation of the grain refinement mechanism using ECP.

Cancelling ore pillars in large-scale coastal gold deposit: A case study in Sanshandao gold mine, China

According to the actual conditions in Sanshandao Gold Mine, the cancelling ore pillars mining method was researched. Firstly, a series of tests for the physical and mechanical characteristics of rock mass were carried out and a quality classification system of rock mass applied in coastal metal deposit was established. Secondly, the reasonable demarcation depth of cancelling ore pillars was simulated using the finite element method, and the simulation results show that the ore pillars can be cancelled below the level of-555 m. Thirdly, a novel layer-backfill mining method of room-pillar alternation was designed to reduce the disturbance and settlement of terrain in mining area. Engineering practice shows that the new mining method enhanced the mining output and relieved rock disturbance. Furthermore, the settlement of the roof strata was small and no disaster occurred. The new mining technology effectively controlled the deformation of the terrain, indicating that the mining of the large-scale gold coastal deposit in Sanshandao Gold Mine was achieved safely, efficiently, and with a low loss rate.