Thermal-electrical Coupled Analysis and Experimental Investigation on Spark Plasma Sintering of SiC Ceramics

Finite element simulations were conducted to study the mechanism of spark plasma sintering. The spark plasma sintering of SiC ceramics was simulated by the Marc software based on the load current curve and temperature-time curve deserved by SPS experiment. The concept of equivalent radiation coefficient was presented and applied during the simulation. The temperature distribution regularity of SiC ceramics sintered by SPS technology was got by thermal-electrical coupled finite element simulation. The experimental results show that by thermal-electrical coupled finite element analysis, the temperature rising and distribution regularity of nonconductive material can be preferable forecasted in the sintering process of SPS. In the initial stage of the heat preservation, the temperature of the central part of the sample has achieved sintering temperature, but now, the temperature of the sample is not uniform. The temperature for each part of the die is also quite different and the sample temperature in the center is higher than that in the edge. In the end of heat preservation, the central temperature of the sample is 50 ℃higher than the required sintering temperature, and the temperature gap for each part of the die decreases gradually.

Electromagnetic–thermal–structural coupling analysis of the ITER edge localized mode coil with flexible supports

In a fusion reactor, the edge localized mode（ELM） coil has a mitigating effect on the ELMs of the plasma. The coil is placed close to the plasma between the vacuum vessel and the blanket to reduce its design power and improve its mitigating ability. The coil works in a high-temperature,high-nuclear-heat and high-magnetic-field environment. Due to the existence of outer superconducting coils, the coil is subjected to an alternating electromagnetic force induced by its own alternating current and the outer magnetic field. The design goal for the ELM coil is to maintain its structural integrity in the multi-physical field. Taking as an example the middle ELM coil（with flexible supports） of ITER（the International Thermonuclear Fusion Reactor）, an electromagnetic–thermal–structural coupling analysis is carried out using ANSYS. The results show that the flexible supports help the three-layer casing meet the static and fatigue design requirements. The structural design of the middle ELM coil is reasonable and feasible. The work described in this paper provides the theoretical basis and method for ELM coil design.

Thermally Induced Vibration Analysis of Flexible Beams Based on Isogeometric Analysis

Spacecraft flexible appendages may experience thermally induced vibrations(TIV)under sudden heating loads,which in consequence will be unable to complete their intended missions.Isogeometric analysis(IGA)utilizes,in an isoparametric concept,the same high order and high continuity non-uniform rational B-splines(NURBS)to represent both the geometry and the physical field of the structure.Compared to the traditional Lagrange polynomial based finite element method where only C0-continuity across elements can be achieved,IGA is geometrically exact and naturally fulfills the C1-continuity requirement of Euler–Bernoulli(EB)beam elements,therefore,does not need extra rotational degrees-of-freedom.In this paper,we present a thermally induced vibration analysis framework based on the isogeometric method where thermal and structural behaviors are coupled.We fully exploited the higher order,higher continuous and geometric exactness of the NURBS basis with both benchmarks and sophisticated problems.In particular,we studied the thermally induced vibrations of the Hubble Space Telescope(HST)solar panel where main factors influencing thermal flutters are studied,and where possible improvements of the analytical reference methods are discussed.Additionally,thermally induced vibrations of the thin-walled lenticular tubes are studied and two new configurations of the tube are proposed to effectively suppress the thermally induced vibrations.Numerical examples of both benchmarks and sophisticated problems confirm the accuracy and efficiency of the isogeometric analysis framework for thermally induced vibration analysis of space structures.

Thermal-Structural Coupled Analysis of ITER Torus Cryo-Pump Housing

An ITER torus cryo-pump housing （TCPH）, which encloses a torus cryo-pump, is connected to a vacuum vessel （VV） by a set of associated double bellows. There are complicated loads due to two different operating states （pumping and regeneration） and foreseeable accidents with the cryo-pump. This paper describes a thermal-structural coupled analysis of the present TCPH according to tho allowatfle stress criteria of RCC-MR, in which the worst cases and outcomes of various load combinations are obtained. Meanwhile, optimization of the structure has been carried oul, to obtain positive analysis results and an adequate safety margin.

考虑热障涂层及冷却结构影响的某F级燃气轮机火焰筒数值研究

以某F级燃气轮机燃烧室火焰筒为研究对象,考虑热障涂层及冷却结构对火焰筒气动传热影响,基于流热固耦合方法对额定工况下的火焰筒进行了内部流场、温度场和应力场分析,并将数值分析结果与火焰筒实际损伤情况进行对比。结果表明:数值分析结果的火焰筒高应力区域与火焰筒实际损伤区域基本吻合,采用流热固耦合方法可以预测火焰筒实际损伤情况;不同位置的热障涂层陶瓷层隔热效果相近;基体和热障涂层陶瓷层在冷却结构附近的区域均为高应力区域。

深中通道钢壳-混凝土组合沉管浇筑变形研究

深中通道沉管管节采用钢壳-混凝土组合结构形式,通过向空钢壳浇筑混凝土预制而成。为评估沉管管节施工后的整体变形,建立了热-结构顺序耦合的分析框架,基于ANSYS APDL及UFPs二次开发模块,分别建立了考虑水化度、日照辐射、大气温度变化的精细温度场模型和考虑混凝土硬化及收缩特性的结构分析模型。通过对足尺管节的温度及应变模拟结果与监测数据的对比,验证了有限元模型的可靠性。在此基础上,分析了日照辐射、大气温度变化等对于管节温度场的影响,同时分析了管节的整体变形模式,以及温度效应、混凝土收缩及自重三种因素对管节整体横向、纵向及竖向变形的影响。结果表明:管节施工过程的温度场表现为时变和空间分布的特征,格仓边部温度受外界气温变化和日照辐射的影响存在周期性波动,而格仓中部温度峰值主要受混凝土自身水化放热特性的控制;管节最终表现为顶板横向及纵向内收,竖向下挠,底板横向及竖向变形不显著;太阳辐射对于结构温度场影响较日气温变化更显著,建议在混凝土温度峰值预测中予以考虑,而日气温变化可采用日平均气温值予以简化;温度效应及材料收缩对管节横向及纵向整体变形影响显著,自重因素导致的变形在横向及纵向的比例为44.3%、11.7%,而在竖向所占比例达92.5%,因而温度效应及材料收缩在管节横向及纵向变形分析中不可忽视;该分析方法可适用于大体积混凝土等结构的温度效应的预测和评估。

Thermal–structure coupling analysis and multi-objective optimization of motor rotor in MSPMSM

With the high speed, the rotor of magnetically suspended permanent magnet synchronous motor(MSPMSM) suffers great thermal stress and mechanical stress resulting from the temperature rise problem caused by rotor losses, which leads to instability and inefficiency.In this paper, the mechanical–temperature field coupling analysis is conducted to analyze the relationship between the temperature field and structure, and multi-objective optimization of a rotor is performed to improve the design reliability and efficiency. Firstly, the temperature field is calculated by the 2 D finite element model of MSPMSM and the method of applying the 2 D temperature result to the 3 D finite element model of the motor rotor equivalently is proposed. Then the thermal–structure coupling analysis is processed through mathematic method and finite element method(FEM),in which the 3 D finite element model is established precisely in a way and approaches the practical operation state further. Moreover, the impact produced by the temperature and structure on the mechanical strength is analyzed in detail. Finally, the optimization mathematical model of the motor rotor is established with Sequential Quadratic Programming-NLPQL selected in the optimization scheme. Through optimization, the strength of the components in the motor rotor increases obviously and satisfies the design requirement, which to a great extend enhances the service life of the MSPMSM rotor.

7FDL-16柴油机气缸盖热结构耦合应力分析

通过CATIA软件进行三维建模,利用Space Claim模块提取流体域,在Fluent模块设置流体边界条件并仿真流动,先后导入Ansys Workbench稳态热和静应力分析模块,设置热边界条件和应力载荷,得到气缸盖的温度场以及热结构耦合应力分布云图。热结构耦合应力分析可得:热应变最大处在火力面鼻梁区,最大变形量为0.002 1 mm,应力最大处在两排气门之间的鼻梁区,最大应力值为398 MPa,安全系数为2.71,满足实际结构工作的要求标准。

BMS电路板多模块协同热-力耦合建模及仿真分析

针对现有电动汽车电池管理系统(BMS)电路板研究仅仅考虑单一功能模块的温度场及其散热效果,缺乏考虑BMS多个功能模块在温度场和力场下的相互影响及协同效应的研究的情况,以某商用BMS电路板为研究对象,采用ANSYS构建了表征BMS多模块协同作用下的热-力耦合数值仿真分析模型并验证了其有效性.在此基础上,针对BMS电路板各功能模块温度场及热变形行为开展了数值仿真研究.结果表明:BMS电路板温度分布不均,最大温差达20.5℃.均衡模块存在积热,温度高达54.4℃.高温导致电路板组件发生热膨胀变形,同时电路板约束诱发均衡模块及供电模块边缘的贴片电阻出现热应力集中,两者共同作用致使BMS均衡模块、供电模块产生凸起翘曲变形,且Z轴热变形量随着温度升高而增大,最大变形量达9.5μm,应针对BMS电路板上积热模块开展散热优化设计.

面向短时/断续工作制的电机系统固–液相变热管理技术及应用发展

固–液相变现象表现出的潜热特性可有效平抑瞬时温升,将其应用于航天航空、奔越式机器人、新能源汽车、数控机床等电机热管理系统,可有效提高短时工作制或断续周期性工作制(S2—S8)下运行的伺服电驱动系统的瞬态性能。为了总结归纳固–液相变材料的电机系统热管理技术及其应用现状,该文针对固–液相变材料特性、系统数值计算与仿真模拟、样机实验测试方法、相变热管理系统结构等4个方面开展调研,并提出亟待解决的关键技术问题。研究发现:目前阶段石蜡和低温熔盐是适合电机系统的最佳相变介质,但仍存在导热系数较低的问题,需通过改性强化解决;通过机壳灌注相变材料,可有效实现温升平抑,但尚缺乏有针对性的热路拓扑设计;采用焓–多孔方法是模拟相变过程的理想手段,但糊状区参数的取值缺乏理论指导;最后,固–液相变过程的测试中侵入式传感器易对电磁、热、流场的自然演变过程产生干扰。

脉冲电流下对AL6061合金进行熔孔止裂与愈合的仿真研究

Al6061铝合金常应用于航空航天领域蒙皮制造,因其中等硬度与低强度的弱点,在承受复杂载荷时容易出现微裂纹,进而影响服役安全可靠性。脉冲电流是一种极速、非平衡的金属材料微小裂纹修复工艺,可以克服该材料不易焊接修复的短板。在既有的实验基础上建立单边预制裂纹缺口模型,采用有限元仿真手段,进行了热-电-力三场耦合数值模拟,计算不同参数下裂纹区域的电场、温度场和应力场分布。使用“生死单元”法模拟止裂熔孔的产生,并获得了不同几何、物理参数下止裂熔孔尺寸变化的规律。结果表明:焦耳热形成的止裂熔孔降低裂尖的集中应力,抑制裂纹扩展,裂纹区域高温区与基体常温区形成温度梯度相互约束产生巨大的热压应力促使裂纹宽度减小,进而直至愈合;初始熔孔尺寸与裂纹长度成正比、与板厚成反比,最佳尺寸直径为0.1 mm以内;电流值和电流加载时间均能控制熔孔生长,电流值一定时,当时间达到0.12 s形成的熔孔尺寸超出最佳止裂尺寸范围。研究成果为特定金属材料的裂纹止裂与愈合提供了机理参考和仿真方法。

长波红外差分干涉仪光栅低温安装结构设计与优化

长波红外差分干涉仪在低温工况下会因光学元件受到非均匀应力作用产生干涉条纹的畸变,从而降低干涉仪系统性能。本文为解决低温工况干涉条纹弯曲畸变问题,基于长波红外差分干涉仪光机系统进行了干涉条纹畸变影响因素分析,结合光-机-热耦合分析方法,对干涉仪系统低温工作状态进行仿真。随后设计了针对影响条纹畸变的关键元件——光栅元件的低温微应力动态稳定支撑安装结构,结构优化后的光栅表面面形均方根(Root Mean Square,RMS)值为3.89×10^(-2) nm,面形峰谷值(Peak to Valley,PV)值为2.21×10^(-1) nm,分别较优化前初始系统的分析结果减小了5个数量级,系统仿真干涉条纹畸变小于1个探测器像元。全系统低温验证试验表明,优化结构可有效抑制干涉条纹畸变,畸变量小于2个探测器像元,试验与仿真计算结果一致性较好,验证了优化分析方法的有效性。该优化方案对提升反射式光学系统结构低温稳定性,提高系统工作能力有较大意义和价值。

工字钢退火过程的有限元仿真及工艺优化

根据工字钢的几何形状和材料特性,采用ANSYS有限元软件建立了工字钢退火过程的热-结构耦合分析模型,并对3种退火工艺的温度场和应力场进行了模拟和分析。结果表明:相比去应力退火和再结晶退火,完全退火工艺的温度最高、热通量最小;去应力退火和再结晶退火可能导致材料内部应力积累,使工字钢的应力分布不均匀;完全退火后材料晶体结构发生了重排和再结晶,使工字钢的热应力和热应变显著减小,使用可靠性提高。

增程式发电机的磁热耦合分析及试验研究

随着新能源技术的日益成熟,增程式发电机对于新能源电动汽车的发展也越来越重要。这种增程式发电机的其本质上为永磁同步电机,特点是体积小,功率大,发热量高,所以计算发电机的损耗和分析其稳态运行温度尤为重要,并为此建造一款新型冷却水道,使其产生的发热量降低。首先运用Maxwell建立电机的二维模型并通过Motor-CAD建立等效热网络模型,采用有限元分析方法对电机进行磁-热双向迭代耦合,加入冷却水道,分析电机在稳态运行状态下的电磁性能以及电机温升。最终通过样机试验验证磁-热双向耦合分析温度场的方法的准确性。

考虑温度变化的复合织构轴承的摩擦学性能仿真

表面微织构化是改善轴承摩擦学性能重要手段之一,目前对于表面微织构的设计多以加工简单的单层形状为主,但在对轴承织构化试验和数值模拟研究中发现,单层微织构在减少摩擦磨损和降低能耗方面仍不够突出。基于圆筛藻壳的多层孔状结构,设计矩形-半球型双层复合微织构,并应用于水润滑轴承的高压区,采用热流固耦合的方法,探究在考虑进水温度变化的条件下、双层复合型织构的尺寸变化和轴承转速对水润滑轴承摩擦性能的影响。结果表明:对于任何进水温度,双层复合型织构轴承的减摩性能优于光滑轴承和单层织构轴承。复合织构尺寸效应对润滑水膜压力影响不稳定,但对摩擦因数的影响相对平稳。另外,在任何温度下,复合型织构轴承的转速越高,润滑水膜压力和摩擦因数越大。研究成果在改善水润滑轴承摩擦学性能方面有更进一步的突破,可为减小摩擦磨损及延长轴承使用寿命的相关研究提供借鉴。

高压反应釜螺纹式快开结构强度分析

为了解决工程中常用的卡箍式及齿啮式快开结构反应釜难于满足介质操作过程中均温性要求的问题,笔者设计了一种均温性能良好的螺纹式快开结构反应釜装置,用于热塑性聚氨酯弹性体(thermoplastic polyurethane elastomer,TPU)材料生产以提高其生产质量。分别建立平盖、碗形盖和凸形盖3种快开结构有限元模型,分析螺纹应力分布情况并进行设计压力工况及热-力耦合工况的应力强度评定。结果表明:3种快开结构的筒体端部内螺纹根部应力整体高于釜盖外螺纹,其应力均随着螺纹扣数增加而减小;2种工况下3种快开结构的最大应力均出现在第1扣螺纹根部,当考虑温度载荷影响时,热应力分别增大了13.97%,9.30%和4.79%,应力和疲劳强度均满足要求。对比表明凸形盖螺纹式快开结构承压承温的综合性能较好。

扁挤压筒内孔形状对结构强度的影响

扁挤压筒是挤压扁宽型材的重要结构件,其结构应力最大值一般发生在内壁上。由于内孔非圆形,应力分布极不均匀,存在较严重的应力集中。内壁的应力集中情况同内孔形状密切相关,也影响了扁挤压筒的整体结构应力状态。采用有限元法对扁挤压筒结构进行热—结构耦合分析,模拟各工况下筒结构受载后变形及应力状态,分别对三种形状内孔的扁挤压筒结构进行强度仿真计算,对比不同内孔形状的筒结构变形、应力状态及工艺可行性,为制造及优化设计提供参考。

基于流-热-固耦合分析的数值模拟及结构优化

为解决等径T型管路应力过大问题,提出一种基于流-热-固耦合分析方法的优化方法对等径T型管结构进行优化。首先,基于流、固力学理论建立T型管多场耦合的数学模型和物理模型,对T型管内流体的速度温度变化情况和管路的等效应力的分布情况进行仿真模拟,在仿真结果的基础上对管路进行结构优化。仿真结果表明:冷热流体的压力差会导致流体产生逆流现象,从而导致管路的上游区等效应力值增大。等径T型管的最大等效应力值出现在主支管交汇的下游内壁面处。优化后管路内壁面最大等效应力值下降约14%,可以有效地延长管路的使用寿命。该方法对提高气体管路设计的可靠性具有一定的实践意义。

实际火灾场景下不锈钢伞状结构倒塌分析

为研究不锈钢伞状结构在实际火灾场景下的倒塌机制,本文以一个缩尺1:4的不锈钢伞状结构火灾试验为基础,建立并验证了有限元分析模型,通过热-结构耦合分析方法,对其在不同火灾场景下的抗火性能进行研究。结果表明:火源位置改变对伞状结构耐火性能有明显影响,当火源处于同一水平高度时,发生在截面面积小的次支杆下方的火灾将引起结构整体倒塌破坏,而当火源位于主支杆下方时,仅引起受火区域内结构的局部破坏,剩余结构仍有一定的承载能力。

高温后带粉刷层钢筋混凝土柱非线性全过程分析

在前人试验研究基础上,采用ANSYS软件对4根未外抹粉刷层RC柱构件高温后的抗震承载性能进行热—力耦合模拟分析,模拟分析数据结果与试验数据结果吻合情况较好。在有限元模型得到验证的基础上,拓展外抹粉刷层RC柱高温后抗震承载性能的热—力耦合数值模拟分析,深入探讨了外抹粉刷层对RC柱承载能力的影响。计算分析表明,粉刷层可有效减少外部高温热量输入构件,构件截面温度增长受抑制,增长相对比较缓慢;粉刷层可有效提高火灾后RC柱的屈服荷载和极限荷载,减缓刚度退化;粉刷层可起到较好的保护作用,有效减轻混凝土结构的火灾损伤。