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.

Temperature field model in surface grinding: a comparative assessment

Grinding is a crucial process in machining workpieces because it plays a vital role in achieving the desired precision and surface quality.However,a significant technical challenge in grinding is the potential increase in temperature due to high specific energy,which can lead to surface thermal damage.Therefore,ensuring control over the surface integrity of workpieces during grinding becomes a critical concern.This necessitates the development of temperature field models that consider various parameters,such as workpiece materials,grinding wheels,grinding parameters,cooling methods,and media,to guide industrial production.This study thoroughly analyzes and summarizes grinding temperature field models.First,the theory of the grinding temperature field is investigated,classifying it into traditional models based on a continuous belt heat source and those based on a discrete heat source,depending on whether the heat source is uniform and continuous.Through this examination,a more accurate grinding temperature model that closely aligns with practical grinding conditions is derived.Subsequently,various grinding thermal models are summarized,including models for the heat source distribution,energy distribution proportional coefficient,and convective heat transfer coefficient.Through comprehensive research,the most widely recognized,utilized,and accurate model for each category is identified.The application of these grinding thermal models is reviewed,shedding light on the governing laws that dictate the influence of the heat source distribution,heat distribution,and convective heat transfer in the grinding arc zone on the grinding temperature field.Finally,considering the current issues in the field of grinding temperature,potential future research directions are proposed.The aim of this study is to provide theoretical guidance and technical support for predicting workpiece temperature and improving surface integrity.

A MODEL FOR NUMERICAL CALCULATION OF UNSTEADYTEMPERATURE FIELD

The model established in this paper for calculating the unsteady temperature field, in which physical parameters varies with temperatures, is simplified as compared with the classical one by defining the heat conductivity as function of temperature and dealing with the latent heat of phase transformation and boundary conditions. The results show that the probability of absolute error less 2℃ between the calculated and measured values in temperature field calculation reaches above 80%.

Investigation on Temperature Field Calibration and Analysis of Wind Tunnel

For wind tunnels,it is essential to conduct temperature and flow field calibration on their test section,which is an important indicator for evaluating the quality of wind tunnel flow fields.In the paper,a truss composed of temperature sensors was used to calibrate the temperature field of a completed wind tunnel section.By adjusting the distance between the temperature measurement truss and the nozzle,as well as the wind speed,the temperature field distribution data at different positions could be obtained.Analyze these data to identify important factors that affect the distribution of temperature field.Simultaneously,the temperature field of the wind tunnel was simulated accordingly.The purpose is to further analyze the fluid heat transfer between air and wind tunnel walls through numerical simulation.Through the above analysis methods,the quality of the temperature field in the wind tunnel has been further verified,providing reference for future wind tunnel tests of relevant models.

Numerical analysis for permafrost temperature field in the short term of permafrost subgrade filling

Purpose-It is of great significance to study the influence of subgrade filling on permafrost temperature field in permafrost area for the smooth construction and safe operation of railway.Design/methodology/approach-The paper builds up the model for the hydrothermal coupling calculation of permafrost using finite element software COMSOL to study how permafrost temperature field changes in the short term after subgrade filling,on which basis it proposes the method of calculation for the concave distortion of freezing front in the subgrade-covered area.Findings-The results show that the freezing front below the subgrade center sinks due to the thermal effect of subgrade filling,which will trigger hydrothermal erosion in case of sufficient moisture inflows,leading to the thawing settlement or the cracking of the subgrade,etc.The heat output of soil will be hindered the most in case of July filling,in which case the sinking and the distortion of the freezing front is found to be the most severe,which the recovery of the permafrost temperature field,the slowest,constituting the most unfavorable working condition.The concave distortion of the freezing front in the subgrade area increases with the increase in temperature difference between the filler and ground surface,the subgrade height,the subgrade width and the volumetric thermal capacity of filler,while decreases with the increase of the thermal conductivity of filler.Therefore,the filler chose for engineering project shall be of small volumetric thermal capacity,low initial temperature and high thermal conductivity whenever possible.Originality/value-The concave distortion of the freezing front under different working conditions at different times after filling can be calculated using the method proposed.

Field and numerical modelling on the stability of underground strata in longwall workings

The longwall method is one of the feasible and efficient underground mining methods for greater depth of workings.Recently,Singareni Collieries Company Limited(SCCL),the largest coal-producing government company in the Southern part of India,has deployed a high capacity(2×1152T capacity)power support system in its Adriyala Longwall Project(ALP)at a depth of 375 m.There was a concern about the stability of the longwall workings and the protective pillars.Thus,research work was carried out with the geotechnical instruments and numerical modelling tools to analyze the stability while retreating the longwall panels.The outcomes revealed that the convergence in the gate roads increased with the longwall face advancement and the area of exposure.The pressure of the powered support legs on the dip side was less than the rise side legs,which implies a stable roof condition over the longwall face.An abutment zone was identified ahead of the line of extraction up to 10e25 m and presumed from the Factor of Safety(FoS)criterion that within this zone,the longwall pillar possibly will be of better stability at every stage of extraction.The results obtained from this study would be helpful for the mining engineers to understand the behaviour of underground strata in longwall workings.

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 modeling of the 2D time-domain transient electromagnetic secondary field of the line source of the current excitation

To effectively minimize the electromagnetic field response in the total field solution, we propose a numerical modeling method for the two-dimensional （2D） time- domain transient electromagnetic secondary field of the line source based on the DuFort- Frankel finite-difference method. In the proposed method, we included the treatment of the earth-air boundary conductivity, calculated the normalized partial derivative of the induced electromotive force （Emf）, and determined the forward time step. By extending upward the earth-air interface to the air grid nodes and the zero-value boundary conditions, not only we have a method that is more efficient but also simpler than the total field solution. We computed and analyzed the homogeneous half-space model and the fiat layered model with high precision--the maximum relative error is less than 0.01% between our method and the analytical method--and the solution speed is roughly three times faster than the total-field solution. Lastly, we used the model of a thin body embedded in a homogeneous half-space at different delay times to depict the downward and upward spreading characteristics of the induced eddy current, and the physical interaction processes between the electromagnetic field and the underground low-resistivity body.

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.

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.

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.

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.

Three dimensional numerical simulation of welding temperature fields in stainless steel

Three kinds of mathematical models representing welding heat sources are presented. Among them, Gaussian model and double ellipsoidal model are used to analyze the thermal distributions with finite element method. At the same time, this paper analyzed the influences of the heat source models, the latent heat and the welding parameters on the temperature distributions. The comparisons between the simulated results and the experiments show double ellipsoidal model is good for three-dimensional numerical simulations. Furthermore, the adaptive mesh technique is applied in the three-dimensional model which greatly reduces the number of nodes and elements in the simulation.

Mathematical Model for Temperature Field of Strip Coil in Cooling and Heating Process

The convection between the strip coil boundary and the surrounding medium was studied, and the mathematical model and boundary conditions for the temperature field of anisotropic strip coil was proposed, and the temperature field of strip coil were calculated by the analytic method.

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 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 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.

A numerical model study on multi-species harmful algal blooms coupled with background ecological fields

Based on systematized physical, chemical, and biological modules, a multi-species harmful algal bloom （HAB） model coupled with background ecological fields was established. This model schematically embod-ied that HAB causative algal species and the background ecological system, quantified as total biomass, were significantly different in terms of the chemical and biological processes during a HAB while the inter-action between the two was present. The model also included a competition and interaction mechanism between the HAB algal species or populations. The Droop equation was optimized by considering tempera-ture, salinity, and suspended material impact factors in the parameterization of algal growth rate with the nutrient threshold. Two HAB processes in the springs of 2004 and 2005 were simulated using this model. Both simulation results showed consistent trends with corresponding HAB processes observed in the East China Sea, which indicated the rationality of the model. This study made certain progress in modeling HABs, which has great application potential for HAB diagnosis, prediction, and prevention.

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.

Temperature Field in Laser Line Scanning Thermography: Analytical Calculation and Experiment

The temperature field in laser line scanning thermography is investigated comprehensively in this work,including analytical calculation and experiment.Firstly,the principle of laser line scanning thermography is analyzed.On this basis,a physical laser line scanning model is proposed.Afterwards,based on Fourier transform(FT)and segregation variablemethod(SVM),the heat conduction differential equation in laser line scanning thermography is derived in detail.The temperature field of the composite-based coatings model with defects is simulated numerically.The results show that the laser line scanning thermography can effectively detect the defects in the model.The correctness of the analytical calculation is verified by comparing the surface temperature distribution obtained by analytical calculation and numerical simulation.Additionally,an experiment is carried out and the changeable surface temperature obtained by analytical calculation is compared with the experimental results.It shows that the error of maximum temperature obtained by analytical calculation and by experiment is 8%with high accuracy,which proves the correctness of analytical calculation and enriches the theoretical foundation of laser line scanning thermography.