Simulation on flow, heat transfer and stress characteristics of large-diameter thick-walled gas cylinders in quenching process under different water spray volumes

Cooling strength is one of the important factors affecting microstructure and properties of gas cylinders during quenching process,and reasonable water spray volume can effectively improve the quality of gas cylinders and reduce production costs.To find the optimal water spray parameters,a fluid-solid coupling model with three-phase flow was established in consideration of water-vapor conversion.The inner and outer walls of gas cylinder with the dimensions of d914 mm×38 mm×12000 mm were quenched using multi-nozzle water spray system.The internal pressure,average heat transfer coefficient(have)and stress of the gas cylinder under different water spray volumes during quenching process were studied.Finally,the mathematical model was experimentally verified.The results show that both the internal pressure and have increase along with the increase of spray volume.The internal pressure increases slowly first and then rapidly,but have increases rapidly first and then slowly.To satisfy hardenability of gas cylinders,the minimum spray volume should not be less than 40 m^3/(h·m).The results of stress indicate that water spray quenching will not cause deformation of bottle body in the range of water volume from 40 to 290 m^3/(h·m).

DRX rules during extrusion process of large-scale thick-walled Inconel 625 pipe by FE method

A thermal-mechanical and micro-macro coupled finite element（FE） model for the hot extrusion process of large-scale thick-walled Inconel 625 pipe was developed based on the DEFORM-2D platform.Then,the influence rules of the key extrusion parameters on the average grain size and grain uniformity of the extruded pipe were revealed.The results show that with the increase of initial billet temperature,extrusion speed and friction coefficient,the grain uniformity is firstly improved and then deteriorated.Larger extrusion ratio leads to more uniform grain distribution.With the increase of initial billet temperature,the average grain size of the pipe first decreases and then increases.Additionally,larger extrusion ratio can bring smaller average grain size.The extrusion speed and friction coefficient have slight effects on the average grain size of the extruded pipe.

A theoretical analysis of vertical dynamic response of large-diameter pipe piles in layered soil

Considering the viscous damping of the soil and soil-pile vertical coupled vibration,a computational model of large-diameter pipe pile in layered soil was established.The analytical solution in frequency domain was derived by Laplace transformation method.The responses in time domain were obtained by inverse Fourier transformation.The results of the analytical solution proposed agree well with the solutions in homogenous soil.The effects of the shear modulus and damping coefficients of the soil at both outer and inner sides of the pipe pile were researched.The results indicate that the shear modulus of the outer soil has more influence on velocity admittance than the inner soil.The smaller the shear modulus,the larger the amplitude of velocity admittance.The velocity admittance weakened by the damping of the outer soil is more obvious than that weakened by the damping of the inner soil.The displacements of the piles with the same damping coefficients of the outer soil have less difference.Moreover,the effects of the distribution of soil layers are analyzed.The results indicate that the effect of the upper soil layer on dynamic response of the pipe pile is more obvious than that of the bottom soil layer.A larger damping coefficient of the upper layer results in a smaller velocity admittance.The dynamic response of the pipe pile in layered soil is close to that of the pipe pile in homogenous soil when the properties of the upper soil layer are the same.

A Theoretical Analysis of the Bearing Performance of Vertically Loaded Large-Diameter Pipe Pile Groups

This paper aims to present a theoretical method to study the bearing performance of vertically loaded large-diameter pipe pile groups.The interactions between group piles result in different bearing performance of both a single pile and pile groups.Considering the pile group effect and the skin friction from both outer and inner soils,an analytical solution is developed to calculate the settlement and axial force in large-diameter pipe pile groups.The analytical solution was verified by centrifuge and field testing results.An extensive parametric analysis was performed to study the bearing performance of the pipe pile groups.The results reveal that the axial forces in group piles are not the same.The larger the distance from central pile,the larger the axial force.The axial force in the central pile is the smallest,while that in corner piles is the largest.The axial force on the top of the corner piles decreases while that in the central pile increases with increasing of pile spacing and decreasing of pile length.The axial force in side piles varies little with the variations of pile spacing,pile length,and shear modulus of the soil and is approximately equal to the average load shared by one pile.For a pile group,the larger the pile length is,the larger the influence radius is.As a result,the pile group effect is more apparent for a larger pile length.The settlement of pile groups decreases with increasing of the pile number in the group and the shear modulus of the underlying soil.

Numerical Simulation and Experimental Research on Microstructural Evolution During Compact Hot Extrusion of Heavy Caliber Thick-Wall Pipe

Compact hot extrusion(CHE) process of heavy caliber thick-wall pipe is a new material-saving production process. In order to reveal the optimum hot extrusion parameters in CHE process, the e ects of the extrusion parameters on the microstructural evolution are investigated systematically. The metadynamic recrystallization(MDRX) kinetic models and grain size models of as-cast P91 steel are established for the first time according to the hot compression tests performed on the Gleeble-3500 thermal-simulation machine. Then a thermal-mechanical and micro-macro coupled hot extrusion finite element(FE) model is established and further developed in DEFORM software. The results indicated that the grain size of the extruded pipe increases with the increasing of initial temperature and extrusion speed, decreases when extrusion ratio increases. Moreover, the grain size is more sensitive to the initial temperature and the extrusion ratio. The optimum hot extrusion parameters are including that, the initial extrusion temperature of 1250 °C, the extrusion ratio of 9 and the extrusion speed of 50 mm/s. Furthermore, in order to verify the simulation precisions, hot extrusion experiment verification on the heavy caliber thick-wall pipe is carried out on the 500 MN vertical hot extrusion equipment. The load–displacement curve of the extrusion process and the grain sizes of the middle part extruded pipe are in good accuracy with the simulation results, which confirms that the hot extrusion FE models of as-cast P91 steel could estimate the hot extrusion behaviors. The proposed hot extrusion FE model can be used to guide the industrial production research of CHE process.

Optimizing Winding Angles of Reinforced Thermoplastic Pipes Based on Progressive Failure Criterion

This paper examines a scheme to optimize the multiple winding angles of reinforced thermoplastic pipes(RTPs)under internal and external pressures.To consider the nonlinear mechanical behavior of the material under changes of winding angle due to deformation,we use three-dimensional(3D)thick-walled cylinder theory with the 3D Hashin failure criterion and theory of the evolution of damage to composite materials,to formulate a model that analyzes the progressive failure of RTPs.The accuracy of the model was verified by experiments.A model to optimize the multiple winding angles of the RTPs was then established using the model for progressive failure analysis and a multi-island genetic algorithm.The optimal scheme for winding angles of RTPs capable of withstanding the maximum internal/external pressure was obtained.The simulation results showed that the ply number of the reinforced layer has a prominent nonlinear effect on the internal and external pressure capacity of the RTPs.Compared with RTPs with a single angle of±55°,the multiple winding angle overlay scheme based on the multi-angle optimization model improved the internal and external pressure capacity of the RTPs,and the improvement in the external pressure capacity was significantly better than the internal pressure carrying capacity.

Prediction of welding residual stress in multipass narrow gap welded pipes with large thickness

The objective of this study is to investigate the influence of post weld heat treatment （PWHT） on the distribution of residual stress in welded pipes with large thickness. The detailed pass-by-pass finite element simulation was developed to study the residual stress in narrow gap multipass welding of pipes with a wall thickness of 150 mm and 89 weld beads. The effect of PWHT on welding residual stress was also investigated by means of numerical analysis. The simulated results show that the hoop stress is tensile stress in the weld region and compressive stress in the parent metal areas adjacent to weld seam. After heat treatment, the residual stresses decrease substantially, and the simulated residual stress is validated by the experimental one. The distribution of the through-wall axial residual stress along the weld center line is a self-equilibrating type.

High-frequency interference in low strain integrity testing of large-diameter pipe piles

The high-frequency interference exists obviously in low strain integrity testing of large-diameter pipe pile when a transientpoint load is applied. An analytical solution of vertical vibratory response of large-diameter pipe piles in low strain testing isdeduced in this paper. The analytical solution is verified by both numerical simulation and model test results. The time-domainvelocity responses on pile top are analyzed. The calculation results indicate that the time-domain responses at various pointssuffer different high-frequency interferences, thus the peak values and phases of different points are different. The influence ofvibratory modes on high-frequency interference is analyzed. It is found that the high-frequency interference at 90° point main-ly derives from the second flexural mode, but for other points it mainly originates from the first flexural mode. The factors af-fecting the frequency and peak value of interference waves have been investigated in this study. The results indicate that thelarger radius angle between the receiving and 90° points leads to greater peak value of high frequency wave crest. The leasthigh-frequency interference is detected at the angle of 90°. The frequency of interference waves is decreased with the increaseof pile radius, while the peak value is almost constant. The frequency is also related to pile modulus, i.e. the larger pile modu-lus results in greater frequency. The peak value varies with impulse width and soil resistance, i.e., the wider impulse width andlarger soil resistance cause smaller peak value. In conclusion, the frequency of interference waves is dependent on the geomet-rical and mechanics characteristics of the piles such as pile radius and modulus, but independent of the external conditionssuch as impulse width and soil resistance. On the other hand, the peak value of interference waves is mainly dependent on theexternal conditions but independent of the geometrical and mechanics characteristics of the piles. In practice, some externalmeasures should be adopted to weaken high-frequency interference such as using soft hammer, hammer cushion and adoptingsuitable receiving point.

Advances in Compact Manufacturing for Shape and Performance Controllability of Large-scale Components-A Review

Research on compact manufacturing technology for shape and performance controllability of metallic components can reanze the simplification and high-reliability of manufacturing process on the premise of satisfying the requirement of macro/micro-structure. It is not only the key paths in improving performance, saving material and energy, and green manufacturing of components used in major equipments, but also the challenging subjects in frontiers of advanced plastic forming. To provide a novel horizon for the manufacturing in the critical components is significant. Focused on the high-performance large-scale components such as bearing rings, flanges, railway wheels, thick-walled pipes, etc, the conventional processes and their developing situations are summarized. The existing problems including multi-pass heating, wasting material and energy, high cost and high-emission are discussed, and the present study unable to meet the manufacturing in high-quality components is also pointed out. Thus, the new techniques related to casting-rolling compound precise forming of rings, compact manufacturing for duplex-metal composite rings, compact manufacturing for railway wheels, and casting-extruding continuous forming of thick-walled pipes are introduced in detail, respectively. The corresponding research contents, such as casting ring blank, hot ring rolling, near solid-state pressure forming, hot extruding, are elaborated. Some findings in through-thickness microstructure evolution and mechanical properties are also presented. The components produced by the new techniques are mainly characterized by fine and homogeneous grains. Moreover, the possible directions for fin＇ther development of those techniques are suggested. Finally, the key scientific problems are first proposed. All of these results and conclusions have reference value and guiding significance for the integrated control of shape and performance in advanced compact manufacturing.

Numerical Simulation of Transient 3-D Turbulent Hested Jet into Crossflow in a Thick-Wall T-Junction Pipe

The present work is to investigate the transient three-dimensional heated turbulent jet into crossflow in a thickwall T-junction pipe using CFD package. Two cases with the jet-to-crossflow velocity ratio of 0.05 and 0.5 are computed, with a finite-volume method utilizing κ-ε model. Comparison of the steady-state computations with measured data shows good qualitative agreement. Transient process of injection is simulated to examine the thermal shock on the T-junction component. Temporal temperature of the component is acquired by thermal coupling with the fluid. Via analysis of the flow and thermal characteristics, factors causing the thermal shock are studied. Optimal flow rates are discussed to reduce the thermal shock.

Feasibility evaluation for excavation of Naghshe Jahan Square subway station by underground methods

In recent years, in reaction to the increasing usage of urban areas, the excavation of underground spaces has been developed. One of the most challenging issues encountered by engineers is the construction of subway stations as large underground spaces at shallow depth with soft surrounding soils. In this paper, Naghshe Jahan Square subway station located in Isfahan, Iran, has been simulated by geomechanical fnite difference method(FDM). This station is located under important historical structures. Therefore, the ground displacement and surface settlement induced by the excavation of the subway station should be strictly controlled. Many of such problems are affected by selected excavation method. For these reasons, different underground excavation methods associated with construction have been studied. In this study, sequential excavation method and large-diameter curved pipe roofng method are used and the numerical results of the two methods are compared. The presence of groundwater table obliges us to choose special techniques for the stability of the ground around the subway station during construction; hence compressed air and ground freezing techniques are utilized in the simulations of the subway station. Finally, after choosing appropriate support systems, the large-diameter curved pipe roofng method with 1.5 m spacing between curved pipes is proposed.