Development of thermal simulation system for heavy section ductile iron solidification

A new reliable thermal simulation system for studying solidification of heavy section ductile iron has been developed using computer feedback control and artificial intelligent methods. Results of idle test indicate that the temperature in the system responses exactly to the inputted control data and the temperature control error is less than ±0.5%. It is convenient to simulate solidification of heavy section ductile iron using this new system. Results of thermal simulation experiments show that the differences in nodularity and number of graphite nodule per unit area in the thermal simulation specimen and the actual heavy section block is less than 5% and 10%, respectively.

Magmatism-Related Thermal Simulation of Volcanic Arcs in the Molucca Sea Bidirectional Subduction System

The bidirectional subduction system,island arc magmatic activities,and thermal structure of the forearc basin in the Molucca Sea are taken into consideration in this study.The active volcanic arcs on both sides of the bidirectional subduction zone in the Molucca Sea are undergoing arc-arc collisions.We applied a finite element thermal simulation method to reconstruct the thermal evolution history of the Molucca Sea Plate based on geophysical data.Then,we analyzed the thermodynamic characteristics of island arc volcanism on both sides of the bidirectional subduction zone.The results showed that at 10Myr,the oceanic ridge of the Molucca Sea Plate was asymmetrically biased to the west,causing this bidirectional subduction to be deeper in the west than in the east.Furthermore,the oceanic ridge subducted under the Sangihe arc at 5.5Myr,causing intermittent cessation of volcanic activities.Due to the convergence of bidirectional subduction,the geothermal gradient in the top 3km depth of the forearc area between the Sangihe and Halmahera arcs decreased from about 60℃km^(−1) at 4Myr to about 38℃km^(−1) today.Finally,within the 45–100 km depth range of the sliding surface of the subduction,anomalously high-temperature zones formed due to shear friction during the bidirectional subduction.

A customized system for simulation of welding thermal process

This paper presents a customized simulation system for analyzing welding temperature field, which is based on Finite elementary Analysis software MSC. Marc. The system has the functions of robustly hexahedral meshing, automated loading of dynamic heat source models for various welding methods and convenient post-processing for welding temperature field. A gene unit algorithm is presented to achieve robust simulation for assembled structure. High order routine method is used to generate various customized routines robustly, which includes Fortran subroutines for welding heat source, Marc command routines for automated modeling, and python subroutines for post-processing etc. With the system, simulation of welding temperature fields can be easily conducted with simple operations.

Effect of t_(8/5) on the microstructure and properties of the HAZ of ASME SA213-T92 steel by thermal simulation

The relationship between the t8/5 and micro-hardness, impact toughness in the heat affected zone （HAZ） of ASME SA213-792 at peak temperature of 1 350 ℃ was studied by thermal simulation. The result shows that the micro-hardness of HAZ rises at the beginning and then decreases with increasing of t8/5 , whereas the impact toughness presents reverse trend. The distribution of precipitates in substrate has great influence on the impact toughness of HAZ. When the t8/5 is 40 s, chain-like precipitates lower the impact toughness of HAZ seriously.

SIMULATION OF WELD THERMAL CYCLE USING THE MODEL OF CARBONITRIDE PARTICLES PRECIPITATION

Based on the chasteal nucleation theory, the kinetic precipitation model of carbon - nitride particles in weld HAZ is proposed. Using the model,welding simulation technology and the quantitative metallo- graphic analysis,the precipitation transformation temperatue (PTT) curve is obtained.The data from the simulated welds are in good apreement with the value that the PTT curves predicated.

MD simulation of a copper rod under thermal shock

In this paper, thermoelastic problem of onedimensional copper rod under thermal shock is simulated using molecular dynamics method by adopting embedded atom method potential. The rod is on axis x, the left outermost surface of which is traction free and the right outermost surface is fixed. Free boundary condition is imposed on the outermost surfaces in direction y and z. The left and right ends of the rod are subjected to hot and cold baths, respectively. Temperature, displacement and stress distributions are obtained along the rod at different moments, which are shown to be limited in the mobile region, indicating that the heat propagation speed is limited rather than infinite. This is consistent with the prediction given by generalized thermoelastic theory. From simulation results we find that the speed of heat conduction is the same as the speed of thermal stress wave. In the present paper, the simulations are conducted using the large-scale atomic/molecular massively parallel simulator and completed visualization software.

SIMULATION IN THERMAL DESIGN FOR ELECTRONIC CONTROL UNIT OF ELECTRONIC UNIT PUMP

The high working junction temperature of power component is the most common reason of its failure. So the thermal design is of vital importance in electronic control unit （ECU） design. By means of circuit simulation, the thermal design of ECU for electronic unit pump （EUP） fuel system is applied. The power dissipation model of each power component in the ECU is created and simulated. According to the analyses of simulation results, the factors which affect the power dissipation of components are analyzed. Then the ways for reducing the power dissipation of power components are carried out. The power dissipation of power components at different engine state is calculated and analyzed. The maximal power dissipation of each power component in all possible engine state is also carried out based on these simulations. A cooling system is designed based on these studies. The tests show that the maximum total power dissipation of ECU drops from 43.2 W to 33.84 W after these simulations and optimizations. These applications of simulations in thermal design of ECU can greatly increase the quality of the design, save the design cost and shorten design time

Modeling and simulation of 3D thermal stresses of large-sized castings in solidification processes

When heavy machines and large scaled receiver system of communication equipment are manufactured, it always needs to produce large-sized steel castings, aluminum castings and etc. Some defects of hot cracking by thermal stress often appear during solidification process as these castings are produced, which results in failure of castings. Therefore predicting the effects of technological parameters for production of castings on the thermal stress during solidification process becomes an important means. In this paper, the mathematical models have been established and numerical calculation of temperature fields by using finite difference method (FDM) and then thermal stress fields by using finite element method (FEM) during solidification process of castings have been carried out. The technological parameters of production have been optimized by the results of calculation and the defects of hot cracking have been eliminated. Modeling and simulation of 3D thermal stress during solidification processes of large-sized castings provided a scientific basis, which promoted further development of advanced manufacturing technique.

Parametric Study by Dynamic Simulation of the Influence of the Air Infiltration Rate and the Convective Thermal Transfer Coefficient on the Thermal Behavior of Residential Buildings Built with Cut Lateritic Blocks

Sustainable building design in dry tropical areas recommends reducing exposure of buildings to solar radiation and/or designing efficient enclosures with satisfactory thermal inertia.We propose in this paper a study of the influence of the infiltration rate in the building and the coefficient of thermal transfer by convection of the walls, on the thermal comfort using TRNSYS software. All the models carried out were validated by recognized scientific criteria, namely correlation （R） and determination （R2） coefficients on the one hand and NBME and CVRMSE coefficients defined by ASHARE, 2002 on the other hand. The results obtained indicate that the modulation of the air infiltration rate allows the simulations on TRNSYS to be compared to in-situ measurements, with an annual average relative difference of 2.86% on the temperature difference. Furthermore, depending on the parameterization of the heat transfer coefficients by convection of the internal and external walls of walls used in the STD, the average annual difference can be reduced by 1% to 4% between the predictions and the measurements.

Thermal Analysis Simulation of Germanium Zone Refining Process Assuming a Constant Radio-Frequency Heating Source

Three-dimensional thermal a nalysis simulation of a horizontal zone refining system is conducted for germanimn semiconductor materials. The considered geometry includes a g＇ral）hite boat filled with germanium placed in a cylindrical quartz tube. A flow of Ar and H2 gas mixture is purged througll the tube. A narrow section of the, boat is assmned to be exposed to a constant heat rate produced b v an rf coil located outside the quartz tube. The results of this analysis provide essential information about various parameters such as the shape of tile molten zone, required power and temperature gradient in the system.

Mechanisms of carbon isotopic fractionation in the process of natural gas generation: Geochemical evidence from thermal simulation experiment

Low maturity coal samples were taken from the Ordos Basin to conduct gold tube thermal simulation experiment in a closed system,and the characteristics of the products were analyzed to find out the fractionation mechanism of carbon isotopes and the causes of abnormal carbon isotopic compositions of natural gas.At the heating rates of 2℃/h(slow)and 20℃/h(rapid),the low maturity coal samples of the Ordos Basin had the maximum yields of alkane gas of 302.74 mL/g and 230.16 mL/g,theδ13C1 ranges of-34.8‰to-23.6‰and-35.5‰to-24.0‰;δ13C2 ranges of-28.0‰to-9.0‰and-28.9‰to-8.3‰;andδ13C3 ranges of-25.8‰to-14.7‰and-26.4‰to-13.2‰,respectively.Alkane gas in the thermal simulation products of rapid temperature rise process showed obvious partial reversal of carbon isotope series at 550℃,and at other temperatures showed positive carbon isotope series.In the two heating processes,theδ13C1 turned lighter first and then heavier,and the non-monotonic variation of theδ13C1 values is because the early CH4 is from different parent materials resulted from heterogeneity of organic matter or the carbon isotope fractionation formed by activation energy difference of early enriched 12CH4 and late enriched 13CH4.The reversal of carbon isotope values of heavy hydrocarbon gas can occur not only in high to over mature shale gas(oil-type gas),but also in coal-derived gas.Through thermal simulation experiment of toluene,it is confirmed that the carbon isotope value of heavy hydrocarbon gas can be reversed and inversed at high to over mature stage.The isotope fractionation effect caused by demethylation and methyl linkage of aromatic hydrocarbons may be an important reason for carbon isotope inversion and reversal of alkane gas at the high to over mature stage.

Thermal Simulation for Two-Phase Liquid Cooling 3D-ICs

This work presents an algorithm for simulating more accurate temperature distribution in two-phase liquid cooling for three-dimensional integrated circuits than the state of-the-art methods by utilizing local multi-linear interpolation techniques on heat transfer coefficients between the microchannel and silicon substrate, and considering the interdependence between the thermal conductivity of silicon and temperature values. The experimental results show that the maximum and average errors are only 9.7% and 6.7% compared with the measurements, respectively.

A Prediction Model of Effective Thermal Conductivity for Metal Powder Bed in Additive Manufacturing

In current research,many researchers propose analytical expressions for calculating the packing structure of spherical particles such as DN Model,Compact Model and NLS criterion et al.However,there is still a question that has not been well explained yet.That is:What is the core factors affecting the thermal conductivity of particles?In this paper,based on the coupled discrete element-finite difference(DE-FD)method and spherical aluminum powder,the relationship between the parameters and the thermal conductivity of the powder(ETC_(p))is studied.It is found that the key factor that can described the change trend of ETC_(p) more accurately is not the materials of the powder but the average contact area between particles(a_(ave))which also have a close nonlinear relationship with the average particle size d_(50).Based on this results,the expression for calculating the ETC_(p) of the sphere metal powder is successfully reduced to only one main parameter d_(50)and an efficient calculation model is proposed which can applicate both in room and high temperature and the corresponding error is less than 20.9%in room temperature.Therefore,in this study,based on the core factors analyzation,a fast calculation model of ETC_(p) is proposed,which has a certain guiding significance in the field of thermal field simulation.

A Precise Model for Simulation of Temperature Distribution in Power Modules

The interaction between the active chips mounted and the same base plate is considered as a thermoelectrical coupling effect.An approach to coupling effect analysis of a multi-chip system is presented with IGBT as a sample.Finite element method is used to evaluate the temperature distribution in power modules.The precise electrothermal model is obtained by fitting the curve of transient thermal impedance with a finite series of exponential terms,in which,the thermal-coupling effect among chips is considered as a prediction of the highest transient temperature of the chips.This model can be used in many thermal monitoring systems.Both ANSYS and PSPICE si- mulation software have been employed,and the simulation results agree with the experimental ones very well.

Higher-order mode analysis for SOLEIL-type superconducting cavity

A 499.8 MHz SOLEIL-type superconducting cavity was simulated and designed for the first time in this paper.The higher-order mode(HOM)properties of the cavity were investigated.Two kinds of coaxial HOM couplers were designed.Using 4 L-type and 4 T-type HOM couplers,the longitudinal impedance and the transverse impedances were suppressed to below 3 kΩand 30 kΩ/m,respectivly.The HOM damping requirements of Hefei Advanced Light Facility(HALF)were satisfied.This paper conducted an in-depth study on the radio frequency(RF)design,multipacting optimization,and thermal analysis of these coaxial couplers.Simulation results indicated that under operating acceleration voltage,the optimized couplers does not exhibit multiplicating or thermal breakdown phenomena.The cavity has the potential to reach a higher acceleration gradient.

Differences and identification on multi-time hydrocarbon generation of carboniferous-permian coaly source rocks in the Huanghua Depression,Bohai Bay Basin

Coal is a solid combustible mineral,and coal-bearing strata have important hydrocarbon generation potential and contribute to more than 12%of the global hydrocarbon resources.However,the deposition and hydrocarbon evolution process of ancient coal-bearing strata is characterized by multiple geological times,leading to obvious distinctions in their hydrocarbon generation potential,geological processes,and production,which affect the evaluation and exploration of hydrocarbon resources derived from coaly source rocks worldwide.This study aimed to identify the differences on oil-generated parent macerals and the production of oil generated from different coaly source rocks and through different oil generation processes.Integrating with the analysis of previous tectonic burial history and hydrocarbon generation history,high-temperature and high-pressure thermal simulation experiments,organic geochemistry,and organic petrology were performed on the Carboniferous-Permian(C-P)coaly source rocks in the Huanghua Depression,Bohai Bay Basin.The oil-generated parent macerals of coal's secondary oil generation process(SOGP)were mainly hydrogen-rich collotelinite,collodetrinite,sporinite,and cutinite,while the oil-generated parent macerals of tertiary oil generation process(TOGP)were the remaining small amount of hydrogen-rich collotelinite,sporinite,and cutinite,as well as dispersed soluble organic matter and unexhausted residual hydrocarbons.Compared with coal,the oil-generated parent macerals of coaly shale SOGP were mostly sporinite and cutinite.And part of hydrogen-poor vitrinite,lacking hydrocarbon-rich macerals,and macerals of the TOGP,in addition to some remaining cutinite and a small amount of crude oil and bitumen from SOGP contributed to the oil yield.The results indicated that the changes in oil yield had a good junction between SOGP and TOGP,both coal and coaly shale had higher SOGP aborted oil yield than TOGP starting yield,and coaly shale TOGP peak oil yield was lower than SOGP peak oil yield.There were significant differences in saturated hydrocarbon and aromatic parameters in coal and coaly shale.Coal SOGP was characterized by a lower Ts/Tm and C31-homohopane22S/(22S+22R)and a higher Pr/n C17compared to coal TOGP,while the aromatic parameter methyl dibenzothiophene ratio(MDR)exhibited coaly shale TOGP was higher than coaly shale SOGP than coaly TOGP than coaly SOGP,and coal trimethylnaphthalene ratio(TNR)was lower than coaly shale TNR.Thus,we established oil generation processes and discriminative plates.In this way,we distinguished the differences between oil generation parent maceral,oil generation time,and oil production of coaly source rocks,and therefore,we provided important support for the evaluation,prediction,and exploration of oil resources from global ancient coaly source rocks.

INFLUENCE OF THE SECOND THERMAL CYCLE ON COARSE- GRAINED ZONE TOUGHNESS OF X70 STEEL

The influence of the second thermal cycle on coarse grained zone (CGHAZ) toughness of X70 steel is studied by weld thermal simulation test, scanning electron microscope and electron microprobe. The results show that the CGHAZ toughness is improved after the second thermal cycle but being heated during the intercritical HAZ (ICHAZ). The CGHAZ toughness decreases evidently after being heated during partially transformed zone, which chiefly results from the carbon segregation to the grain boundaries of primal austenite, thus forming high carbon martensite austenite (M A) constituent and bringing serious intercritically reheated coarse grain HAZ (IRCGHAZ) embrittlement.

Simulation of casting deformation based on mold surface element method

Deformation of casting during the solidification process has puzzled many engineers and scientists for years. In order to attain the goal of near-net forming by casting, numerical simulation is a powerful tool. Traditional methods compute the thermal stress of both the casting and the mold. This method suffers the problem of massive calculation and failure of convergence. This paper proposes an improved Mold Surface Element Method, the main idea of which is to use the surface elements instead of body elements to express the interactions between the casting and the mold. The proposed method shows a high computation efficiency and provides satisfactory precision for engineering. Two practical casting products were used to verify the proposed method. The simulated results agree well with those observed in practical products. The proposed method is believed to benefit production practice and to provide theoretical guidance.

Optimal design of vegetation in residential district with numerical simulation and field experiment

Vegetation plays a key role in improving wind environment of residential districts,and is helpful for creating a comfortable and beautiful living environment.The optimal design of vegetation for wind environment improvement in winter was investigated by carrying out field experiments in Heqingyuan residential area in Beijing,and after that,numerical simulation with SPOTE(simulation platform for outdoor thermal environment) experiments for outdoor thermal environment of vegetation was adopted for comparison.The conclusions were summarized as follows:1) By comparing the experimental data with simulation results,it could be concluded that the wind field simulated was consistent with the actual wind field,and the flow distribution impacted by vegetation could be accurately reflected;2) The wind velocity with vegetation was lower than that without vegetation,and the wind velocity was reduced by 46%;3) By adjusting arrangement and types of vegetation in the regions with excessively large wind velocity,the pedestrian-level wind velocity could be obviously improved through the simulation and comparison.

Molecular dynamics study of thermal stress and heat propagation in tungsten under thermal shock

Using molecular dynamics （MD） simulation, we study the thermal shock behavior of tungsten （W）, which has been used for the plasma facing material （PFM） of tokamaks. The thermo-elastic stress wave, corresponding to the collective displacement of atoms, is analyzed with the Lagrangian atomic stress method, of which the reliability is also analyzed. The stress wave velocity corresponds to the speed of sound in the material, which is not dependent on the thermal shock energy. The peak pressure of a normal stress wave increases with the increase of thermal shock energy. We analyze the temperature evolution of the thermal shock region according to the Fourier transformation. It can be seen that the “obvious” velocity of heat propagation is less than the velocity of the stress wave; further, that the thermo-elastic stress wave may contribute little to the transport of kinetic energy. The heat propagation can be described properly by the heat conduction equation. These results may be useful for understanding the process of the thermal shock of tungsten.