Study on Numerical Simulation of Mold Filling and Heat Transfer in Die Casting Process

A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.

A Study on Numerical Simulation of Core-Shooting Process

In order to evaluate the main factors influencing the core-shooting process and to optimize the design of core boxes, the fluid-particle (air-sand) model has been built based on the two-phase flow theory. The fluid phase, air, and the particulate phase, sand granules, have been treated as a continuum. By using this model, it is possible to simulate the flow and compaction behavior of sand particles during the core-shooting process. To benchmark the calculated results, the shooting process has been recorded with a digital high speed camera, and the inlet condition of sand particles has also been achieved by using the camera. The preliminary results have showed that the calculation is in agreement with the testing results.

A numerical model of coastline deformation for sandy beach at downstream of a jetty

A reformed numerical model based on the 'one-line theory' for beach deformation is presented. In this model, the change of beach slope during coastline procession is considered.A wave numerical model combined with wave refraction, diffraction and reflection is used to simulate wave climate to increase numerical accuracy.The results show that the numerical model has a good precision based on the adequate field data. The results can be applied to practical engineering.

Numerical simulation of non-gaussian process of wind waves

In this paper further mathematical analysis on 'correlation transfer technique' by Polge el al. is carried out, the tenable conditions and the extent of suitability for the said method are proved as well. In consideration of the influence of skewness of the sea surface elevation on spectral shape, a 'quasi-correlation transfer techique' is developed by the modification of the simulated target spectrum. Meanwhile, the numerical simulation of the non-Gaussian process of wind waves is carried out in view of the two conditions of the surface elevation probability distribution and the spectrum. By using its simulated results, the influence of skewness of the sea surface elevation on two parameters in the distribution of wave heights (which had been fitted by using the Weibull distribution) is analysed. The 'quasi- correlation tranfer technique' is verified and compared with the selection wave data observed in the Jiaozhou Bay in the period of 1980 to 1981. Results make clear (hat, as far as the statistical distribution of the wave heights and the distribution of the maximum (minimum) values of the sea surface elevation are concerned, the said method is obviously superior to the conventional mothed of the linear wave superposition, and that the simulated results are closer to the observation data.

Numerical Study on Dry Deposition Processes in Canopy Layer

A coupling model between the canopy layer(CL) and atmospheric boundary layer (ABL) for the study of dry deposition velocity is developed. The model consists of six parts: chemical species conservation equation including absorptive factor; the species uptake action including detailed vertical variation of absorptive element in CL; momentum exchange in CL which is represented by a first-order closure momentum equation with an additional larger-scale diffusive term; momentum exchange in ABL which is described by a complete set of the ABL turbulent statistic parameters; absorptivity (or solubility or reflection) at the surface including effects of the physical and chemical characters of the species, land type, seasonal and diurnal variations of the meteorological variables; and deposition velocity derived by distributions of the species with height in CL. Variational rules of the concentration and deposition velocity with both height and time are simulated with the model for both corn and forest canopies. Results predicted with the bulk deposition velocity derived in the paper consist well with experimental data.

On Numerical Modelling of Industrial Powder Compaction Processes for Large Deformation of Endochronic Plasticity at Finite Strains

Compaction processes are one the most important par ts of powder forming technology. The main applications are focused on pieces for a utomotive, aeronautic, electric and electronic industries. The main goals of the compaction processes are to obtain a compact with the geometrical requirements, without cracks, and with a uniform distribution of density. Design of such proc esses consist, essentially, in determine the sequence and relative displacements of die and punches in order to achieve such goals. A.B. Khoei presented a gener al framework for the finite element simulation of powder forming processes based on the following aspects; a large displacement formulation, centred on a total and updated Lagrangian formulation; an adaptive finite element strategy based on error estimates and automatic remeshing techniques; a cap model based on a hard ening rule in modelling of the highly non-linear behaviour of material; and the use of an efficient contact algorithm in the context of an interface element fo rmulation. In these references, the non-linear behaviour of powder was adequately desc ribed by the cap plasticity model. However, it suffers from a serious deficiency when the stress-point reaches a yield surface. In the flow theory of plasticit y, the transition from an elastic state to an elasto-plastic state appears more or less abruptly. For powder material it is very difficult to define the locati on of yield surface, because there is no distinct transition from elastic to ela stic-plastic behaviour. Results of experimental test on some hard met al powder show that the plastic effects were begun immediately upon loading. In such mater ials the domain of the yield surface would collapse to a point, so making the di rection of plastic increment indeterminate, because all directions are normal to a point. Thus, the classical plasticity theory cannot deal with such materials and an advanced constitutive theory is necessary. In the present paper, the constitutive equations of powder materials will be discussed via an endochronic theory of plasticity. This theory provides a unifi ed point of view to describe the elastic-plastic behaviour of material since it places no requirement for a yield surface and a ’loading function’ to disting uish between loading an unloading. Endochronic theory of plasticity has been app lied to a number of metallic materials, concrete and sand, but to the knowledge of authors, no numerical scheme of the model has been applied to powder material . In the present paper, a new approach is developed based on an endochronic rate independent, density-dependent plasticity model for describing the isothermal deformation behavior of metal powder at low homologous temperature. Although the concept of yield surface has not been explicitly assumed in endochronic theory, it is shown that the cone-cap plasticity yield surface (Fig.1), which is the m ost commonly used plasticity models for describing the behavior of powder materi al can be easily derived as a special case of the proposed endochronic theory. Fig.1 Trace of cone-cap yield function on the meridian pl ane for different relative density As large deformation is observed in powder compaction process, a hypoelastic-pl astic formulation is developed in the context of finite deformation plasticity. Constitutive equations are stated in unrotated frame of reference that greatly s implifies endochronic constitutive relation in finite plasticity. Constitutive e quations of the endochronic theory and their numerical integration are establish ed and procedures for determining material parameters of the model are demonstra ted. Finally, the numerical schemes are examined for efficiency in the model ling of a tip shaped component, as shown in Fig.2. Fig.2 A shaped tip component. a) Geometry, boundary conditio n and finite element mesh; b) density distribution at final stage of

The Design of a Graphical User Environment for Numerical Simulation of Powder Forming Processes

As computer simulation increasingly supports engine er ing design and manufacture, the requirement for a computer software environment providing an integration platform for computational engineering software increas es. A key component of an integrated environment is the use of computational eng ineering to assist and support solutions for complex design. Computer methods fo r structural, flow and thermal analysis are well developed and have been used in design for many years. Many software packages are now available which provi de an advanced capability. However, they are not designed for modelling of powde r forming processes. This paper describes the powder compaction software (PCS_SU T), which is designed for pre- and post-processing for computational simulatio n of the process compaction of powder. In the PCS_SUT software, the adaptive analysis of transient metal powder forming process is simulated by the finite element method based on deformation theories . The error estimates and adaptive remeshing schemes are applied for updated co -ordinate analysis. A generalized Newmark scheme is used for the time domain di scretization and the final nonlinear equations are solved by a Newton-Raphson p rocedure. An incremental elasto-plastic material model is used to simulate the compaction process. To describe the constitutive model of nonlinear behaviour of powder materials, a combination of Mohr-Coulomb and elliptical yield cap model is applied. This model reflects the yielding, frictional and densification char acteristics of powder along with strain and geometrical hardening which occurs d uring the compaction process. A hardening rule is used to define the dependence of the yield surface on the degree of plastic straining. A plasticity theory for friction is employed in the treatment of the powder-tooling interface. The inv olvement of two different materials, which have contact and relative movement in relation to each other, must be considered. A special formulation for friction modelling is coupled with a material formulation. The interface behaviour betwee n the die and the powder is modelled by using an interface element mesh. In the present paper, we have demonstrated pre- and post-processor finite elem ent software, written in Visual Basic, to generate the graphical model and visua lly display the computed results. The software consist of three main part: · Pre-processor: It is used to create the model, generate an app ropriate finite element grid, apply the appropriate boundary conditions, and vie w the total model. The geometric model can be used to associate the mesh with th e physical attributes such as element properties, material properties, or loads and boundary conditions. · Analysis: It can deal with two-dimensional and axi-symmetric applications for linear and non-linear behaviour of material in static and dyna mic analyses. Both triangular and quadrilateral elements are available in the e lement library, including 3-noded, 6-noded and 7-noded (T6B1) triangles and 4 -noded, 8-noded and 9-noded quadrilaterals. The direct implicit algorithm bas ed on the generalized Newmark scheme is used for the time integration and an aut omatic time step control facility is provided. For non-linear iteration, choice s among fully or modified Newton-Raphson method and quasi-Newton method, using the initial stiffness method, Davidon inverse method or BFGS inverse method, ar e possible. · Post-processor: It provides visualization of the computed resu lts, when the finite element model and analysis have been completed. Post-proce ssing is vital to allow the appropriate interpretation of the completed results of the finite element analysis. It provides the visual means to interpret the va st amounts of computed results generated. Finally, the powder behaviour during the compaction of a multi-level component is numerically simulated by the PCS_SUT software, as shown in Fig.1. The predict ive compaction forces at different displacements are computed and compared with the available experimental

Simulation Research on the Effect of Spreading Process Parameters on the Quality of Lunar Regolith Powder Bed in Additive Manufacturing

Lunar surface additive manufacturing with lunar regolith is a key step in in-situ resource utilization.The powder spreading process is the key process,which has a major impact on the quality of the powder bed and the precision of molded parts.In this study,the discrete element method(DEM)was adopted to simulate the powder spreading process with a roller.The three powder bed quality indicators,including the molding layer offset,voidage fraction,and surface roughness,were established.Besides,the influence of the three process parameters,which are roller’s translational speed,rotational speed,and powder spreading layer thickness on the powder bed quality indicators was also analyzed.The results show that with the reduction of the powder spreading layer thickness and the increase of the rotational speed,the offset increased significantly;when the translational speed increased,the offset first increased and then decreased,which resulted in an extreme value;with the increase of the layer thickness and the decrease of the translational speed,the values for voidage fraction and surface roughness significantly reduced.The powder bed quality indicators were adopted as the optimization objective,and the multi-objective parameter optimization was carried out.The predicted optimal powder spreading parameters and powder bed quality indicators were then obtained.Moreover,the optimal values were then verified.This study can provide informative guidance for in-situ manufacturing at the moon in future deep space exploration missions.

An iterative wavefront sensing algorithm for high-contrast imaging systems

Wavefront sensing from multiple focal plane images is a promising technique for high-contrast imaging systems.However,the wavefront error of an optics system can be properly reconstructed only when it is very small.This paper presents an iterative optimization algorithm for the direct measurement of large static wavefront errors from only one focal plane image.We first measure the intensity of the pupil image to get the pupil function of the system and acquire the aberrated image on the focal plane with a phase error that will be measured.Then we induce a dynamic phase on the tested pupil function and calculate the associated intensity of the reconstructed image on the focal plane.The algorithm will then try to minimize the intensity difference between the reconstructed image and the aberrated test image in the focal plane,where the induced phase is a variable of the optimization algorithm.The simulation shows that the wavefront of an optical system can theoretically be reconstructed with high precision,which indicates that such an iterative algorithm may be an effective way to perform wavefront sensing for high-contrast imaging systems.

Fast compression and reconstruction of astronomical images based on compressed sensing

With the fast increase in the resolution of astronomical images, the question of how to process and transfer such large images has become a key issue in astronomy. We propose a new real-time compression and fast reconstruction algorithm for astronomical images based on compressive sensing techniques. We first reconstruct tile Original signal with fewer measurements, according to its compressibility. Then, based on the characteristics of astronomical images, we apply Daubechies orthogonal wavelets to obtain a sparse representation. A matrix representing a random Fourier ensembleis used to obtain a sparse representation in a lower dimensional space. For reconstructing the image, we propose a novel minimum total variation with block addptive sensing to balance the accuracy and eomputation time. Our experimental results show that the proposed algorithm can efficiently reconstruct colorful astronomicai images with high resolution and improve the applicability of compressed sensing.

NUMERICAL EXPERIMENT WITH PROCESSES FOR EFFECT OF AUSTRALIAN COLD AIR ACTIVITY ON EAST-ASIAN SUMMER MONSOON

Based on diagnostic results,a numerical study is made of the processes of Australian cold air activity affecting East Asian summer monsoon by using Kuo-Qian P-σ incorporated coordinate five-layer primitive equation spherical band model.Analysis is done of the response to the Southern Hemisphere circulation with and without cold air activity in Australia of the flow,rainfall and diabatic heating fields in the monsoon area of Asia,especially,East Asia,with special attention to the intensification and northward march of the monsoon due to the activity.It is found that the processes for the effect transmission are very analogous to the meridional propagation of quasi-40-day oscillation,together with the meridional wind disturbance showing south-north travel and the flow/rainfall fields exhibitirg corresponding movement in this direction,only with a 12-day lag.

NUMERICAL SIMULATION OF MICROPHYSICAL PROCESSES IN CUMULONIMBUS——PART Ⅱ CASE STUDIES OF SHOWER,HAILSTORM AND TORRENTIAL RAIN

A shower cloud observed in Jiangxi,a hailstorm observed in Hebei and“75.8”torrential rain in Henan are simulated with our microphysical model in a one-dimensional framework.The model,using the radio- sonde data as input,gets its output which shows agreement in many aspects as compared with observations in each case.The glaciation of small cumulus cloud,low precipitation efficiency of hailstorm and the per- sistence of torrential rain are demonstrated.It is also shown that the Bergeron process has little influence, but the warm-rain process plays an important role in the formation of precipitation in cumulonimbus with a warm cloud base.

A NUMERICAL SIMULATION OF THE GEOSTROPHIC ADJUSTMENT PROCESS

In this paper,a numerical simulation of the geostrophic adjustment process with C-grid network is illustrated.A difference scheme which has the energy and potential vorticity conserving relation consistent with the differential equations is given,and the effect of some time difference schemes on dispersion of the gravity-inertia wave is discussed.An improved forward-backward time integration scheme is proposed for keeping the computational stability.The effect of various boundary conditions for a finite region model On the gravity-inertia wave is shown by some calculated results.

Accounting for Polychromatic Light in Virtual Shack-Hartmann Wavefront Sensing

Virtual Shack-Hartmann wavefront sensing(vSHWS)has some significant advantages and is promising for aberration measurement in the field of biomedical optical imaging.The illumination sources used in vSHWS are almost broadband,but are treated as monochromatic sources(only using center wavelength)in current data processing,which may cause errors.This work proposed a data processing method to take into account the multiple wavelengths of the broadband spectrum,named multiple-wavelength centroid-weighting method.Its feasibility was demonstrated through a series of simulations.A wavefront generated with a set of statistical human ocular aberrations was used as the target wavefront to evaluate the performance of the proposed and current methods.The results showed that their performance was very close when used for the symmetrical,but the wavefront error of the proposed method was much smaller than that of the current method when used for the asymmetrical spectrum,especially for the broader spectrum.These results were also validated by using 20 sets of clinical human ocular aberrations including normal and diseased eyes.The proposed method and the obtained conclusions have important implications for the application of vSHWS.

Transient simulation of regression rate on thrust regulation process in hybrid rocket motor

The main goal of this paper is to study the characteristics of regression rate of solid grain during thrust regulation process. For this purpose, an unsteady numerical model of regression rate is established. Gas–solid coupling is considered between the solid grain surface and combustion gas.Dynamic mesh is used to simulate the regression process of the solid fuel surface. Based on this model, numerical simulations on a H2O2/HTPB（hydroxyl-terminated polybutadiene） hybrid motor have been performed in the flow control process. The simulation results show that under the step change of the oxidizer mass flow rate condition, the regression rate cannot reach a stable value instantly because the flow field requires a short time period to adjust. The regression rate increases with the linear gain of oxidizer mass flow rate, and has a higher slope than the relative inlet function of oxidizer flow rate. A shorter regulation time can cause a higher regression rate during regulation process. The results also show that transient calculation can better simulate the instantaneous regression rate in the operation process.