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.

Mechanism of Thermally Radiative Prandtl Nanofluids and Double-Diffusive Convection in Tapered Channel on Peristaltic Flow with Viscous Dissipation and Induced Magnetic Field

The application of mathematical modeling to biological fluids is of utmost importance, as it has diverse applicationsin medicine. The peristaltic mechanism plays a crucial role in understanding numerous biological flows. In thispaper, we present a theoretical investigation of the double diffusion convection in the peristaltic transport of aPrandtl nanofluid through an asymmetric tapered channel under the combined action of thermal radiation andan induced magnetic field. The equations for the current flow scenario are developed, incorporating relevantassumptions, and considering the effect of viscous dissipation. The impact of thermal radiation and doublediffusion on public health is of particular interest. For instance, infrared radiation techniques have been used totreat various skin-related diseases and can also be employed as a measure of thermotherapy for some bones toenhance blood circulation, with radiation increasing blood flow by approximately 80%. To solve the governingequations, we employ a numerical method with the aid of symbolic software such as Mathematica and MATLAB.The velocity, magnetic force function, pressure rise, temperature, solute (species) concentration, and nanoparticlevolume fraction profiles are analytically derived and graphically displayed. The results outcomes are compared withthe findings of limiting situations for verification.

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.

Development of Mathematical Model of Slag Flow Field and Temperature Field in ESR System

The heat transfer phenomena and driving forces of slag bath flow in ESR process were analyzed, and the mathematical models in ESR system were reviewed and evaluated. The electromagnetic force is the main driving force for the flow formation in the ESR slag pool, and the temperature difference in the pool creates a convective flow in the system. The shape of the electrode tip has an effect on electromagnetic field distribution in slag pool, thus affects the flow pattern. Finally an improved mathematical model of slag pool flow was proposed.

Flow and Temperature Fields in Slab Continuous Casting Molds

In order to develop super-board and super-thick slabs, the flow and temperatur fields were studied in slab continuous casting molds under different practical conditions, such as slab dimensions, with-drawing slab speed, design of nozzles, and superheat tempera-ture. The results showed that it is preferred to incline nozzle bores downwards and the submerged depth of the nozzles is best kept be-tween 250-300 mm. In addition, the solidified shell is thicker at the wide face than that at the narrow face, while the thin points alongthe wide face ekist both in the center and in the some area toward each respective end.

The influence of charge characteristics of suspension droplets on the ion flow field in different temperatures and humidity

In order to clarify the charging characteristics of suspension droplets in ion flow field under different temperatures and humidity,the effective charging factor used to characterize the charging characteristics of suspension droplets is introduced in this paper,and a calculation method of charging factor is proposed based on the upstream finite element method(FEM).Then,the charging factor under different temperatures and humidity is calculated,and the analytic expression of the charging factor considering the influence of temperature and humidity is obtained by fitting the calculation results.The influence of suspension droplets on the ion flow field is analyzed.The results show that the charging factor is small and increases little with the relative humidity when the relative humidity is less than 60%,and the charging factor is large and increases rapidly with the relative humidity when the relative humidity is more than 60%.At the same relative humidity,the charging factor increases linearly with the temperature.The influence of charged suspension droplets on the ion flow field can be ignored when the relative humidity is less than 60%and must be considered under high temperature and humidity.The calculation method and analytic expression of the charging factor proposed in this paper can be used to model of ion flow field considering the influence of temperature and humidity and provide technical support for the construction of HVDC transmission lines across high temperature and humidity.

Flow Field and Temperature Field in GaN-MOCVD Reactor Based on Computational Fluid Dynamics Modeling

Metal organic chenlical vapor deposition （AIOCVD） growth systems arc one of the. main types of equipment used for growing single crystal materials, such as GaN. To obtain fihn epitaxial materials with uniform performanee, the flow field and ternperature field in a GaN-MOCVD reactor are investigated by modeling and simulating. To make the simulation results more consistent with the actual situation, the gases in the reactor are considered to be compressible, making it possible to investigate the distributions of gas density and pressure in the reactor. The computational fluid dynamics method is used to stud,v the effects of inlet gas flow velocity, pressure in the reactor, rotational speed of graphite susceptor, and gases used in the growth, which has great guiding~ significance for the growth of GaN fihn materials.

Numerical Investigation on the Flow and Temperature Fields in an Inductively Coupled Plasma Reactor

This paper gives a numerical study on the flow and temperature fields in an induced plasma reactor, which worked in 0.5 ATM with air as a working gas. We employed a two-dimensional mode of an inductively coupled plasma to calculate the temperature and flow field of the reactor as well as the generator. The algorithm is based on the solutions of the two-dimensional continuity, momentum, and energy equations in term of vorticity, stream function and enthalpy. An upwind finite-difference scheme was adopted to solve those equations with appropriate boundary conditions. The computed results show that there is a flat region with little parameter change in the reactor, that the diameter of the region is not much larger than that of the generator and that a deep change of parameter exists in the outer side of the region.

Simulation of Temperature and Flow Field by Three Dimension Finite ElementMethod for Castex Process of AS Wire

Castex of AS wire is a new technology of near net shape. To study the variation of temperature and velocity of liquid (or semisolid) aluminum during dynamic solidification the numerical simulation was carried out with the theory of heat-transfer and hydrodynamics by means of 3-dimensional finite element method. From simulation results, it is found that the variation of temperature and velocityis mainly influenced by the casting temperature of aluminum, rotating speed of Castex wheel and flow of cooling water. Among theseinfluencing factors, the casting temperature distributes most to the length of liquid phase metal. Moreover, the faster the metal solidifies,the higher the metal there moves with the overall trend of descending from the bottom of the wheel to the shoe wall as well as from sidewalls to the center of wheel groove. In comparison with the practical value, the simulation is reliable.

Causes of geothermal fields and characteristics of ground temperature fields in China

There are many arguments on energy sources and main controlling factors of geothermal fields, so a systematic study on the distribution of ground temperature fields shall be necessary. In this paper the thermal conduction forward method of geothermal field is used to simulate cooling rate of abnormal heat sources and heat transfer of the paleo-uplift model. Combined with a large number of geothermal field exploration cases and oil exploration well temperature curves of domestic and foreign, the following conclusions are drawn:(1) According to the magmatic activity time, the magmatism activities are divided into two categories: Magma active areas(activity time < 500 000 years) and weak/magma inactive areas(activity time > 500 000 years). The latter has a fast cooling rate(the cooling time of the magma pocket buried around 10 km is less than 200 000 years) after it has intruded into the shallow layer and it has no direct contribution to modern geothermal fields;(2) China belongs to a weak/magma inactive area such as Tengchong region and Qinghai-Tibet region because the chronological data of these regions show that its magma activity time is more than 500 000 years;(3) The temperature of most geothermal fields can be obviously divided into three segments in the vertical direction: A high geothermal gradient segment(Segment H) at the surface, then a low geothermal gradient segment(Segment L) at a secondary depth, and finally a lower temperature segment(Segment D) at a deeper depth. The temperature isoline presents a mirror reflection relation on the temperature profile, indicating that geothermal field is dominated by heat conduction, rather than having an abnormally high temperature "heat source" to provide heat;(4) Near-surface(0-5 km) materials' lateral heterogeneity caused by tectonic movement shall probably be the main controlling factor of ground temperature fields.

Asymptotic solutions for the asymmetric flow in a channel with porous retractable walls under a transverse magnetic field

The self-similarity solutions of the Navier-Stokes equations are constructed for an incompressible laminar flow through a uniformly porous channel with retractable walls under a transverse magnetic field. The flow is driven by the expanding or contracting walls with different permeability. The velocities of the asymmetric flow at the upper and lower walls are different in not only the magnitude but also the direction. The asymptotic solutions are well constructed with the method of boundary layer correction in two cases with large Reynolds numbers, i.e., both walls of the channel are with suction, and one of the walls is with injection while the other one is with suction. For small Reynolds number cases, the double perturbation method is used to construct the asymptotic solution. All the asymptotic results are finally verified by numerical results.

Numerical study on surrounding rock mass temperature field of Kangding tunnel no.2 considering wind flow

Based on the Kangding Tunnel No.2 project,this study analyzes the heat exchange between air and the rock mass surrounding the tunnel under wind flow by the finite difference method.The influence of factors on the temperature field of a tunnel in cold regions,including ventilation and initial conditions,is investigated.The results show that:1)The lower the air temperature,the greater the wind speed,the larger the rock mass temperature influence circle and the greater the frozen depth;2)When the wind speed is less than 3 m/s,its change has an obvious impact on the rock mass temperature;3)For every drop of 5C in air temperature,the frozen depth increases by about 5 m,indicating that the air temperature is an essential factor affecting the rock mass temperature regime;4)The higher the initial rock mass temperature is,the smaller the influence circle on the rock mass is.And to a certain extent,it determines the temperature distribution in the rock mass within a specific range from the wall surface.

Flow Pattern and Temperature Distribution in HMCZ Silicon Melt

The axial and radial convective flow,temperature fluctuation and distribution in the HMCZ silicon melt are studied tentatively.The experimental results show that the axial and radial convective speeds,the tempera- ture variation and the radial temperature gradient,parallel to magnetic field and near melt surface,all decrease,but the axisymmetry of temperature distribution no longer exists when the magnetic field is applied.

Study on application and numerical simulation of the airflow temperature distribution rule in drifting tunnel

According to the law of conservation in the state of turbulent flow, the differential equation describing the airflow temperature distribution in drifting tunnel is derived, By theoretical analysis and field measurement of the airflow and thermal process in mine, theoretical analysis and systematic flow are developed. By PHONENICS program, the numerical simulation is processed, and the changing rule of airflow temperature with various parameters in drifting tunnel is derived. The airflow temperature in drifting tunnel decreases as the airflow velocity increases in a way of negative power exponent, and elevates linearly as the temperature of the incoming airflow elevates.

Fluid Flow and Solidification Simulation in Beam Blank Continuous Casting Process With 3D Coupled Model

Based on turbulent theory, a 3D coupled model of fluid flow and solidification was built using finite difference method and used to study the influence of superheating degree and casting speed on fluid flow and solidification, analyze the interaction between shell and molten steel, and compare the temperature distribution under different technological conditions. The results indicate that high superheating degree can lengthen the liquid-core depth and make the crack and breakout possible, so suitable superheating should be controlled within 35℃ according to the simulation results. Casting speed which is one of the most important technological parameters of improving production rate, should be controlled between 0. 85 m/min and 1.05 m/min and the caster has great potential in the improvement of blank quality.

Fluid Flow and Heat Transfer Characteristic of Outer and Inner Half Coil Jackets

The physical models of the outer and inner half coil jackets were simplified to two types of coiled ducts.The mathematic models of incompressible fluid at the condition of laminar flow and heat transfer in the two types of jackets for cooling process reactor were set up and solved by the semi-implicit method for pressure linked equa-tions consistent （SIMPLEC） algorithm based on a control volume method.The flow and temperature fields were given and the effects of Dean and Prandtl numbers on flow and heat transfer were studied.The results show that flow in the inner half coil jacket is found to exhibit transition of secondary flow pattern from two vortices to four vortices when the Dean number increases,but that in the outer half coil jacket is not found.The critical Dean num-ber is about 96.The inner half coil jacket has stronger heat transfer ability than the outer half coil jacket and this superiority is more evident with larger Prandtl number.However,as the Dean number is greater than 105,the flow resistance enhances more severely in the inner jacket than the outer jacket.For both jackets,the centers of the heated wall are the poorest for heat transfer.

Numerical prediction of vortex flow and thermal separation in a subsonic vortex tube

This work was aimed at gaining understanding of the physical behaviours of the flow and temperature separation process in a vortex tube. To investigate the cold mass fraction’s effect on the temperature separation, the numerical calculation was carried out using an algebraic Reynolds stress model (ASM) and the standard k-ε model. The modelling of turbulence of com-pressible, complex flows used in the simulation is discussed. Emphasis is given to the derivation of the ASM for 2D axisymmet-rical flows, particularly to the model constants in the algebraic Reynolds stress equations. The TEFESS code, based on a staggered Finite Volume approach with the standard k-ε model and first-order numerical schemes, was used to carry out all the computations. The predicted results for strongly swirling turbulent compressible flow in a vortex tube suggested that the use of the ASM leads to better agreement between the numerical results and experimental data, while the k-ε model cannot capture the stabilizing effect of the swirl.

Coupled Modeling of Electromagnetic Fleld,Fluid Flow,Heat Transfer and Solidification During Conventional DC Casting and Low Ftequency Electrmagnetic Casting of 7xxx Aluminum Alloys

A comprehensive mathematical model has been developed to describe the interaction of the multiple physics fields during the conventional DC casting and LFEC (low frequency electromagnetic casting) process. The model is based on a combination of the commercial finite element package ANSYS and the commercial finite volume package FLUENT, with the former for the calculation of the electromagnetic field and the latter for the calculation of the magnetic driven fluid flow, heat transfer and solidification. Moreover, the model has been verified against the temperature measurements obtained from two 7XXX aluminum alloy billets of 200mm diameter, cast during the conventional DC casting and the LFEC casting processes. In addition, a measurement of the sump shape of the billets were carried out by using addition melting metal of Al-30%Cu alloy into the billets during casting process. There was a good agreement between the calculated results and the measured results. Further, comparison of the calculated results during the LFEC process with that during the conventional DC casting process indicated that velocity patterns, temperature profiles and the sump depth are strongly modified by the application of a low frequency electromagnetic field during the DC casting.

DECAY OF VORTEX VELOCITY AND DIFFUSION OF TEMPERATURE IN A GENERALIZED SECOND GRADE FLUID

The fractional calculus approach in the constitutive relationship model of viscoelastic fluid was introduced. The velocity and temperature fields of the vortex flow of a generalized second fluid with fractional derivative model were described by fractional partial differential equations. Exact analytical solutions of these differential equations were obtained by using the discrete Laplace transform of the sequential fractional derivatives and generalized Mittag-Leffler function. The influence of fractional coefficient on the decay of vortex velocity and diffusion of temperature was also analyzed.

Design and Enhancement of Thermal Flow Characteristic in an Annular Diffuser under Turbulent Flow

The annular diffuser is an expansion area, which, despite its simple structure, is very important in some engineering and thermal applications. In the present research, numerical simulations were performed to investigate the temperature field and flow structure characteristics in an annular diffuser. The hub of the annular diffuser consisted of a straight semi-dimpled tube SSDT. Three different diffuser wall angles (α) 1.8°, 3.6° and 5.4° with inlet Reynolds number 1.5 × 104?were studied in details with air as a working fluid. The computational fluid dynamics CFD was used to simulate the model in a turbulent flow. The standard k-ε turbulence model was used to complete the governing equations. The numerical results, mainly the temperature distribution, pressure drop and velocity distribution for the airflow in the annular diffuser fitted with SSDT for different diffuser wall angles α were obtained and compared. It was observed that as the wall diffuser angle α increases, the enhancement of the temperature distribution and the velocity distribution decrease while the pressure drop rate increases. The maximum temperature distribution and velocity distribution were completed by diffuser wall angle α1 = 1.8° whereas, the highest pressure drop achieved by diffuser wall angle α3 = 5.4°.