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 simulation of flow field deposition and erosion characteristics around bridge-road transition section

Wind-sand flow generates erosion and deposition around obstacles such as bridges and roadbeds, resulting in sand damage and endangering railway systems in sandy regions. Previous studies have mainly focused on the flow field around roadbeds, overlooking detailed examinations of sand particle erosion and deposition patterns near bridges and roadbeds. This study employs numerical simulations to analyze the influence of varying heights and wind speeds on sand deposition and erosion characteristics at different locations: the bridge-road transition section(side piers), middle piers, and roadbeds. The results show that the side piers, experience greater accumulation than the middle piers. Similarly, the leeward side of the roadbed witnesses more deposition compared to the windward side. Another finding reveals a reduced sand deposition length as the vertical profile, in alignment with the wind direction, moves further from the bridge abutments at the same clearance height. As wind speeds rise, there’s a decline in sand deposition and a marked increase in erosion around the side piers, middle piers and roadbeds. In conclusion, a bridge clearance that’s too low can cause intense sand damage near the side piers, while an extremely high roadbed may lead to extensive surface sand deposition. Hence, railway bridges in areas prone to sandy winds should strike a balance in clearance height. This research provides valuable guidelines for determining the most suitable bridge and roadbed heights in regions affected by wind and sand.

Flow and sound fields of scaled high-speed trains with different coach numbers running in long tunnel

Segregated incompressible large eddy simulation and acoustic perturbation equations were used to obtain the flow field and sound field of 1:25 scale trains with three,six and eight coaches in a long tunnel,and the aerodynamic results were verified by wind tunnel test with the same scale two-coach train model.Time-averaged drag coefficients of the head coach of three trains are similar,but at the tail coach of the multi-group trains it is much larger than that of the three-coach train.The eight-coach train presents the largest increment from the head coach to the tail coach in the standard deviation(STD)of aerodynamic force coefficients:0.0110 for drag coefficient(Cd),0.0198 for lift coefficient(Cl)and 0.0371 for side coef-ficient(Cs).Total sound pressure level at the bottom of multi-group trains presents a significant streamwise increase,which is different from the three-coach train.Tunnel walls affect the acoustic distribution at the bottom,only after the coach number reaches a certain value,and the streamwise increase in the sound pressure fluctuation of multi-group trains is strengthened by coach number.Fourier transform of the turbulent and sound pressures presents that coach number has little influence on the peak frequencies,but increases the sound pressure level values at the tail bogie cavities.Furthermore,different from the turbulent pressure,the first two sound pressure proper orthogonal decomposition(POD)modes in the bogie cavities contain 90%of the total energy,and the spatial distributions indicate that the acoustic distributions in the head and tail bogies are not related to coach number.

Flow field, sedimentation, and erosion characteristics around folded linear HDPE sheet sand fence: Numerical simulation study

Wind and sand hazards are serious in the Milan Gobi area of the Xinjiang section of the Korla Railway. In order to ensure the safe operation of railroads, there is a need for wind and sand protection in heavily sandy areas. The wind and sand flow in the region is notably bi-directional. To shield railroads from sand, a unique sand fence made of folded linear high-density polyethylene(HDPE) is used, aligning with the principle that the dominant wind direction is perpendicular to the fence. This study employed field observations and numerical simulations to investigate the effectiveness of these HDPE sand fences in altering flow field distribution and offering protection. It also explored how these fences affect the deposition and erosion of sand particles. Findings revealed a significant reduction in wind speed near the fence corner;the minimum horizontal wind speed on the leeward side of the first sand fence(LSF) decreased dramatically from 3 m/s to 0.64 m/s. The vortex area on the LSF markedly impacted horizontal wind speeds. Within the LSF, sand deposition was a primary occurrence. As wind speeds increased, the deposition zone shrank, whereas the positive erosion zone expanded. Close to the folded corners of the HDPE sand fence, there was a notable shift from the positive erosion zone to a deposition zone. Field tests and numerical simulations confirmed the high windproof efficiency(WE) and sand resistance efficiency(SE) in the HDPE sand fence. Folded linear HDPE sheet sand fence can effectively slow down the incoming flow and reduce the sand content, thus achieving good wind and sand protection. This study provides essential theoretical guidance for the design and improvement of wind and sand protection systems in railroad engineering.

Flow field simulation and establishment for mathematical models of flow area of spool valve with sloping U-shape notch machined by different methods

Precise function expression of the flow area for the sloping U-shape notch orifice versus the spool stroke was derived. The computational fluid dynamics was used to analyze the flow features of the sloping U-shape notch on the spool, such as mass flow rates, flow coefficients, effiux angles and steady state flow forces under different operating conditions. At last, the reliability of the mathematical model of the flow area for the sloping U-shape notch orifice on the spool was demonstrated by the comparison between the orifice area curve derived and the corresponding experimental data provided by the test. It is presented that the bottom arc of sloping U-shape notch （ABU） should not be omitted when it is required to accurately calculate the orifice area of ABU. Although the theoretical flow area of plain bottom sloping U-shape notch （PBU） is larger than that of ABU at the same opening, the simulated mass flow and experimental flow area of ABU are both larger than these of PBU at the same opening, while the simulated flow force of PBU is larger than that of ABU at the same opening. Therefore, it should be prior to adapt the ABU when designing the spool with proportional character.

Bulking factor of the strata overlying the gob and a three-dimensional numerical simulation of the air leakage flow field

The present study examines the results of the researches related to the gob bulking factor carried out at home and abroad.A mathematical function of a three-dimensional gob bulking factor is described based on a three-dimensional gob model.The method of taking value for interstice and permeability ratios is also proposed.The law of air leakage of fully mechanized top coal is researched in this study.The results show that the speed of air flow near the upper and lower crossheadings is higher than that in the central section of the gob at the same distance from the working face.When the amount of air at the working face exceeds a critical amount,the width of the spontaneous combustion zone in the upper and lower crossheadings is also larger than that in the central section.In this situation,the key is preventing the coal left in the upper and lower crossheadings from self-igniting.Reducing the amount of air at the working face can decrease the width of the spontaneous combustion zone,especially the width near the upper and lower crossheadings.This also moves the spontaneous combustion zone in the direction of the working face.It can prevent the coal in the gob from self-igniting by making the coal left in the crossheadings to be inert and by effectively controlling the amount of air at the working face.

Modeling and simulation of muzzle flow field of railgun with metal vapor and arc

During the electromagnetic railgun launching process,there will be a complex flow field with high temperature in the muzzle area because of the high-speed friction,transition and seco ndary arc-ignition.This paper models the muzzle area of railgun when the projectile is far away from the muzzle,and the dynamic simulation of the flow field with secondary arc in the muzzle area is carried out based on the magneto hydrodynamic equations.Meanwhile,a multi-component plasma transport model is used to analyze the muzzle arc plasma flow process of the mixed gas of Al vapor and the air.Furthermore,the pressure boundary conditions are fitted by the dynamic mesh simulation results.The current and voltage of the muzzle are obtained through the emission experiment of the railgun experimental prototype.We load the current data into the simulation model and the voltage of experiments and simulations are compared,which proves the accuracy of the simulation.Then the plasma temperature and the composition of Al vapor in the muzzle flow process are analyzed in-depth.

Numerical simulation of electro-magnetic and flow fields of TiAl melt under electric field

This article aims at building an electromagnetic and fluid model, based on the Maxwell equations and Navier-Stokes equations, in TiAl melt under two electric fields.FEM (Finite Element Method) and APDL (ANSYS Parametric Design Language) were employed to perform the simulation, model setup, loading and problem solving.The melt in molds of same cross section area with different flakiness ratio (i.e.width/depth) under the load of sinusoidal current or pulse current was analyzed to obtain the distribution of electromagnetic field and flow field.The results show that the induced magnetic field occupies sufficiently the domain of the melt in the mold with a flakiness ratio of 5:1.The melt is driven bipolarly from the center in each electric field.It is also found that the pulse electric field actuates the TiAl melt to flow stronger than what the sinusoidal electric field does.

Process simulation and optimization of flow field in wet electrostatic precipitator

To improve the dust removal performance of the wet electrostatic precipitator(WESP), a flow field optimization scheme was proposed via CFD simulation in different scales. The simplified models of perforated and collection plates were determined firstly. Then the model parameters for the resistance of perforated and collection plates, obtained by small-scale flow simulation, were validated by medium-scale experiments. Through the comparison of the resistance and velocity distribution between simulation results and experimental data, the simplified model is proved to present the resistance characteristics of perforated and collection plates accurately. Numerical results show that after optimization, both the flow rate and the pressure drop in the upper room of electric field regions are basically equivalent to those of the lower room, and the velocity distribution in flue inlet of WESP becomes more uniform. Through the application in practice, the effectiveness and reliability of the optimization scheme are proved, which can provide valuable reference for further optimization of WESP.

Structure optimization and flow field simulation of plate type high speed on-off valve

There is a relatively complex flow state inside the high speed on-off valve,which often produces low pressure area and oil reflux in the high-speed opening and closing process of the spool,causing cavitation and vortex and other phenomena.These phenomena will affect the stability of the internal flow field of the plate valve and the flow characteristics of the high speed on-off valve.Aiming at the problems of small flow rate and instability of internal flow field,a new spool structure was designed.The flow field models of two-hole and three-hole plate spools with different openings were established,and software ANSYS Workbench was chosen to mesh the model.The standard k−εturbulence model was selected for numerical simulation using FLUENT software.The pressure distribution and velocity distribution under the same pressure and different opening degree were obtained.The structure and parameters of the optimization model were also obtained.The stability analysis of flow field under different pressure was carried out.The results demonstrate that the three-hole spool has a similar flow field change with the two-hole spool,but it does not create a low pressure zone,and the three-hole spool can work stably at 2 MPa or less.This method improves the appearance of low pressure area and oil backflow in the process of high speed opening and closing of spool.The stability of flow field and the flow rate of high speed switch valve are improved.Finally,the products designed in this paper are compared with existing hydraulic valve products.The results show that the three-hole plate type high speed on-off valve designed in this paper maintains the stability of the internal flow field under the condition of 200 Hz and large opening degree,and realizes the increase of flow rate.

Numerical Simulation of Coupled Molten Steel Flow and Temperature Fields in Compact Strip Production Casting

Based on the casting manufacture practice of steel slabs by CSP technology, the flow and the temperature fields of the funnel mould and the secondary cooling segment were simulated using the commercial code, CFX4. Compared with other physical investigations, the correlative data of the present simulation results are in good agreement with them. Therefore, a more comprehensive survey for metallurgy characteristic of the flow and the temperature fields in CSP continuous casting process can be achieved.

The mesoscale numerical simulation of the flow field of the Hainan Island and the Leizhou Peninsula

The flow field over Hainan Island and the Leizhou Peninsula in summer and winter is discussed with three-dimensional mesoscale model developed in the University of Virginia and using the representative meteorological data of January and July.Simulation results indicate that the local weather characteristics over the Hainan Island are distinctly influenced by theWuzhi Mountain terrain. The cloudy or rainfall weather over the northeast of the Wuzhi Mountain occurs easily, under proper large-scale conditions of flow, temperature and humidity. while west wind prevails. The overcast or rainfall weather is often induced by strong convection in the afternoon over west of the Hainan Island under easterly prevailing wind.

Mathematical Modeling,Field Calibration and Numerical Simulation of Low-Speed Mixed Traffic Flow in Cities

Ｗｉｔｈｔｈｅｒａｐｉｄｄｅｖｅｌｏｐｍｅｎｔｏｆｔｒａｎｓｐｏｒｔａｔｉｏｎａｎｄａｕｔｏｍｏｂｉｌｅｉｎｄｕｓｔｒｙ，ｔｈｅｃｏｎｆｌｉｃｔｂｅｔｗｅｅｎｍｏｔｏｒｍａｎｕｆａｃｔｕｒｅａｎｄｈｉｇｈｗａｙｃｏｎｓｔｒｕｃｔｉｏｎｂｅｃｏｍｅｓｓ...

Numerical Simulation of Tripolar Vortex in Dusty Plasma with Sheared Flow and Sheared Magnetic Field

This article presents a study we have made of one class of coherent structures of the tripolar vortex. Considering the sheared flow and sheared magnetic field which are common in the thermonuclear plasma and space plasma, we have simulated the dynamics of the tripolar vortex. The results show that the tripolar vortex is largely stable in most cases, but a strongly sheared magnetic field will make the structure less stable, and lead it to decays into single vortices with the large space scale. These results are consistent with findings from former research about the dipolar vortex.

Numerical Simulation of 3D Flow Field and Flow-Induced Noise Characteristics in a T-Shaped Reducing Tee Junction

The so-called T-shaped reducing tees are typically used to divide,change and control(to a certain extent)the flow direction in pipe networks.In this study,the Ffowcs Williams–Hawkings(FW-H)equation and the Large Eddy Simulation(LES)methods are used to simulate the flow-induced noise related to T-shaped reducing tees under different inlet flow velocities and for different pipe diameter ratios.The results show that the maximum flow velocity,average flow velocity,and vorticity in the branch pipe increase gradually as the related diameter decreases.Strong vorticity and secondary flows are also observed in the branch pipe,and the associated violent pressure fluctuations are found to be the main sources of flow-induced noise.In particular,as the pipe diameter ratio decreases from 1 to 0.45,the Total Sound Pressure Level(TSPL)increases by 6.8,6.26,and 7.43 dB for values of the inlet flow velocity of 1,2,and 3 m/s,respectively.The distribution characteristics of the flow-induced noise in the frequency domain follow similar trends for different pipe diameter ratios.

Research on buffer structure and flow field simulation of swash plate plunger type hydraulic transformer

In order to solve the problem of excessive noise and vibration during the operation of the hydraulic transformer,an optimization method of valve plate damping hole structure is proposed to alleviate the phenomenon of pressure shock.Firstly,the mathematical model of oil pressure gradient in the plunger cavity is established,and the incremental equation of pressure change is derived.Secondly,a kind of buffering structure is proposed,the corresponding relationship between the pressure change and the envelopment angle of the buffering hole and the aperture size is determined by analyzing the oil pressure change curve in the plunger cavity.Finally,the flow field models with buffering holes are established,and the transient simulation of the pressure change process under the optimal solution is carried out with ANSYS software and the flow field pressure distribution contours are obtained.Through the analysis of simulation results,it is concluded that the optimal envelope angle of the three buffer holes ofA-T-B-Ais 5°,and the optimal aperture is 1.8 mm,1.6 mm,and 1.7 mm,respectively.The buffer hole can achieve a better-buffering effect in the range of variable pressure angle[0°,101°].The buffer hole structure can effectively alleviate the pressure shock and reduce the noise level,which lays a foundation for the design and theoretical research of hydraulic transformers.

Optimization of operating conditions and structure parameters of zinc electrolytic cell based on numerical simulation for electrolyte flow

The physical and mathematical model of an operating electrowinning cell was established, and the flow of electrolyte was numerically simulated by the commercial software Fluent. The results indicate that there are two circulations at the surface flow where part of electrolyte backflows to the inlet from the side of cell, and the rest flows directly to the outlet, and the separation of two circulations with opposite direction occurs at the 20th pair of anode-cathode. This phenomenon was observed in the real operation. The electrolyte flows into the space between anode and cathode from the side portion of the cell. Meanwhile, the interelectrode effective flow rate （IEFR） is put forward to describe quantitively the flow field characteristics and is defined as the ratio of electrolyte flow between the anode and cathode to the total flow area. The influences of structure parameters and operating conditions on IEFR, such as the inlet angle, the volumetric flow rate, the inlet position and the height of steel baffles were simulated. The inlet position has a significant influence on the IEFR and its optimal value is 0.9 m below free surface. The inlet angle should be in the range from -10° to 10°. IEFR is in linear proportion with the volumetric flow rate, and the height of the steel baffle has little influence on the flow field.

Research on numerical simulation of flow field in shallow-bath dense-medium separator

介绍了浅槽重介分选机的结构、工作原理和技术特点，并采用Fluent软件，对浅槽重介分选机内部的流场进行了分析和研究，得出了各主要位置的速度和速度变化规律。揭示了浅槽重介分选机在分选过程中的悬浮液体流场形态及运动规律，以为其结构设计和改进提供理论依据。

COUPLED SIMULATION OF 3D ELECTRO-MAGNETO-FLOW FIELD IN HALL-HEROULT CELLS USING FINITE ELEMENT METHOD

Two full 3D steady mathematical models are developed by finite element method （FEM） to calcalate coupled physics fields. the electro-magnetic model is built and solved first and so is the fluid motion model with the acquired electromagnetic force as source body forces in Navier-Stokes equations. Effects caused by the ferromagnetic shell, busbar system around, and open boundary problem as well as inside induced current were considered in terms of the magnetic field. Furthermore, a new modeling method is found to set up solid models and then mesh them entirely with so-called structuralized grids, namely hex-mesh. Examples of 75kA prebaked cell with two kinds of busbar arrangements are presented. Results agree with those disclosed in the literature and confirm that the coupled simulation is valid. It is also concluded that the usage of these models facilitates the consistent analysis of the electric field to magnetic field and then flow motion to the greater extent, local distributions of current density and magnetic flux density are very much dependent on the cell structure, the steel shell is a shield to reduce the magnetic field and flow pattern is two dimensional in the main body of the metal pad.

Simulation and Analysis on the Two-Phase Flow Fields in a Rotating-Stream-Tray Absorber by Using Computational Fluid Dynamics

The flow field of gas and liquid in a φ150mm rotating-stream-tray (RST) scrubber is simulated by using computational fluid dynamic (CFD) method. The sismulation is based on the two-equation RNG κ-ε turbulence model, Eulerian multiphase model, and a real-shape 3D model with a huge number of meshes. The simulation results include detailed information about velocity, pressure, volume fraction and so on. Some features of the flow field are obtained: liquid is atomized in a thin annular zone; a high velocity air zone prevents water drops at the bottom from flying towards the wall; the pressure varies sharply at the end of blades and so on. The results will be helpful for structure optimization and engineering design.