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.

Numerical simulation of flow field deposition and erosion characteristics around bridge-road transition section

Wind-sand flow generates erosion and deposition around obstacles such as bridges and roadbeds, resulting in sand damage and endangering railway systems in sandy regions. Previous studies have mainly focused on the flow field around roadbeds, overlooking detailed examinations of sand particle erosion and deposition patterns near bridges and roadbeds. This study employs numerical simulations to analyze the influence of varying heights and wind speeds on sand deposition and erosion characteristics at different locations: the bridge-road transition section(side piers), middle piers, and roadbeds. The results show that the side piers, experience greater accumulation than the middle piers. Similarly, the leeward side of the roadbed witnesses more deposition compared to the windward side. Another finding reveals a reduced sand deposition length as the vertical profile, in alignment with the wind direction, moves further from the bridge abutments at the same clearance height. As wind speeds rise, there’s a decline in sand deposition and a marked increase in erosion around the side piers, middle piers and roadbeds. In conclusion, a bridge clearance that’s too low can cause intense sand damage near the side piers, while an extremely high roadbed may lead to extensive surface sand deposition. Hence, railway bridges in areas prone to sandy winds should strike a balance in clearance height. This research provides valuable guidelines for determining the most suitable bridge and roadbed heights in regions affected by wind and sand.

Flow field, sedimentation, and erosion characteristics around folded linear HDPE sheet sand fence: Numerical simulation study

Wind and sand hazards are serious in the Milan Gobi area of the Xinjiang section of the Korla Railway. In order to ensure the safe operation of railroads, there is a need for wind and sand protection in heavily sandy areas. The wind and sand flow in the region is notably bi-directional. To shield railroads from sand, a unique sand fence made of folded linear high-density polyethylene(HDPE) is used, aligning with the principle that the dominant wind direction is perpendicular to the fence. This study employed field observations and numerical simulations to investigate the effectiveness of these HDPE sand fences in altering flow field distribution and offering protection. It also explored how these fences affect the deposition and erosion of sand particles. Findings revealed a significant reduction in wind speed near the fence corner;the minimum horizontal wind speed on the leeward side of the first sand fence(LSF) decreased dramatically from 3 m/s to 0.64 m/s. The vortex area on the LSF markedly impacted horizontal wind speeds. Within the LSF, sand deposition was a primary occurrence. As wind speeds increased, the deposition zone shrank, whereas the positive erosion zone expanded. Close to the folded corners of the HDPE sand fence, there was a notable shift from the positive erosion zone to a deposition zone. Field tests and numerical simulations confirmed the high windproof efficiency(WE) and sand resistance efficiency(SE) in the HDPE sand fence. Folded linear HDPE sheet sand fence can effectively slow down the incoming flow and reduce the sand content, thus achieving good wind and sand protection. This study provides essential theoretical guidance for the design and improvement of wind and sand protection systems in railroad engineering.

Research on numerical simulation of flow field in shallow-bath dense-medium separator

介绍了浅槽重介分选机的结构、工作原理和技术特点，并采用Fluent软件，对浅槽重介分选机内部的流场进行了分析和研究，得出了各主要位置的速度和速度变化规律。揭示了浅槽重介分选机在分选过程中的悬浮液体流场形态及运动规律，以为其结构设计和改进提供理论依据。

Numerical simulation and analysis of solid-liquid two-phase threedimensional unsteady flow in centrifugal slurry pump

Based on RNG k-ε turbulence model and sliding grid technique, solid-liquid two-phase three-dimensional(3-D) unsteady turbulence of full passage in slurry pump was simulated by means of Fluent software. The effects of unsteady flow characteristics on solid-liquid two-phase flow and pump performance were researched under design condition. The results show that clocking effect has a significant influence on the flow in pump, and the fluctuation of flow velocity and pressure is obvious, particularly near the volute tongue, at the position of small sections of volute and within diffuser. Clocking effect has a more influence on liquid-phase than on solid-phase, and the wake-jet structure of relative velocity of solid-phase is less obvious than liquid-phase near the volute tongue and the impeller passage outlet. The fluctuation of relative velocity of solid-phase flow is 7.6% smaller than liquid-phase flow at the impeller outlet on circular path. Head and radial forces of the impeller are 8.1% and 85.7% of fluctuation, respectively. The results provide a theoretical basis for further research for turbulence, improving efficient, reducing the hydraulic losses and wear. Finally, field tests were carried out to verify the operation and wear of slurry pump.

Bulking factor of the strata overlying the gob and a three-dimensional numerical simulation of the air leakage flow field

The present study examines the results of the researches related to the gob bulking factor carried out at home and abroad.A mathematical function of a three-dimensional gob bulking factor is described based on a three-dimensional gob model.The method of taking value for interstice and permeability ratios is also proposed.The law of air leakage of fully mechanized top coal is researched in this study.The results show that the speed of air flow near the upper and lower crossheadings is higher than that in the central section of the gob at the same distance from the working face.When the amount of air at the working face exceeds a critical amount,the width of the spontaneous combustion zone in the upper and lower crossheadings is also larger than that in the central section.In this situation,the key is preventing the coal left in the upper and lower crossheadings from self-igniting.Reducing the amount of air at the working face can decrease the width of the spontaneous combustion zone,especially the width near the upper and lower crossheadings.This also moves the spontaneous combustion zone in the direction of the working face.It can prevent the coal in the gob from self-igniting by making the coal left in the crossheadings to be inert and by effectively controlling the amount of air at the working face.

Numerical simulation of electro-magnetic and flow fields of TiAl melt under electric field

This article aims at building an electromagnetic and fluid model, based on the Maxwell equations and Navier-Stokes equations, in TiAl melt under two electric fields.FEM (Finite Element Method) and APDL (ANSYS Parametric Design Language) were employed to perform the simulation, model setup, loading and problem solving.The melt in molds of same cross section area with different flakiness ratio (i.e.width/depth) under the load of sinusoidal current or pulse current was analyzed to obtain the distribution of electromagnetic field and flow field.The results show that the induced magnetic field occupies sufficiently the domain of the melt in the mold with a flakiness ratio of 5:1.The melt is driven bipolarly from the center in each electric field.It is also found that the pulse electric field actuates the TiAl melt to flow stronger than what the sinusoidal electric field does.

Numerical Simulation of High Speed Rotating Waterjet Flow Field in a Semi Enclosed Vacuum Chamber

In this paper,a three dimension model is built according to real surface cleaner in airport runway rubber mark cleaning vehicle and numerical simulation of this model is carried out using Ansys Fluent software.After comparison and analysis of the flow fields between high speed rotating waterjet and static waterjet formerly studied by other researchers,the influences of different standoff distances from nozzle outlet to runway surface and rotation speeds on rubber mark cleaning effect are simulated and analyzed.Results show the optimal operation parameters for the simulated model and quantitative advices are given for design,manufacture and operation of the airport runway rubber mark cleaning vehicle.

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.

The mesoscale numerical simulation of the flow field of the Hainan Island and the Leizhou Peninsula

The flow field over Hainan Island and the Leizhou Peninsula in summer and winter is discussed with three-dimensional mesoscale model developed in the University of Virginia and using the representative meteorological data of January and July.Simulation results indicate that the local weather characteristics over the Hainan Island are distinctly influenced by theWuzhi Mountain terrain. The cloudy or rainfall weather over the northeast of the Wuzhi Mountain occurs easily, under proper large-scale conditions of flow, temperature and humidity. while west wind prevails. The overcast or rainfall weather is often induced by strong convection in the afternoon over west of the Hainan Island under easterly prevailing wind.

NUMERICAL SIMULATION ANALYSIS OF EXTERNAL FLOW FIELD OF WAGON-SHAPED CAR AT THE MOMENT OF PASSING

In the course of studying on aerodynamic change and its effect on steering stability and controllability of an automobile in passing, because of multi interaction streams, it is difficult to use traditional methods, such as wind tunnel test and road test. If the passing process of an automobile is divided into many time segments, so as to avoid the use of moving mesh which takes large calculation resource and CPU processing time in calculating, the segments are simulated with computational fluid dynamics （CFD） method, then the approximate computational results about external flow field will be obtained. On the basis of the idea, the change of external flow field of wagon-shaped car at the moment of passing is simulated through solving three-dimensional, steady and uncompressible N-S equations with finite volume method. Numerical simulation analysis of side force coefficient, stream lines, body surface pressure distribution of wagon-shaped car are presented and a preliminary discussion of aerodynamic characteristics of correlative situations is obtained. Finally, the C3 -x/l curve of side force coefficient（C3） of car following relative distance （x/l） between cars is obtained. By comparison, the curve is coincident well with the experimental data, which shows creditability of numerical simulation methods presented.

Mathematical Modeling,Field Calibration and Numerical Simulation of Low-Speed Mixed Traffic Flow in Cities

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INFLUENCE OF EXTERNAL MAGNETIC FIELD ON THE FLOW FIELD IN MOLTEN SEMICONDUCTOR OF CZOCHRALSKI CRYSTAL GROWTH——A NUMERICAL SIMULATION

Numerical results show that an external magnetic field may influence significantly the flow pattern in the molten semiconductor of Czochralski crystal growth. The melt flow could be pronouncedly damped by a magnet. ic field with the intensity of several thousands Gauss, while the temperature field is affected only in a less extent by the magnetic field.

Numerical Simulation of the Air Jet Flow Field in the Melt Blowing Process

The theoretical model of the flow field of the dual slot die in melt blowing process is founded. The model is solved numerically with finite difference method. The distributions of the air velocity component in x direction along x-axis and y-axis and the air temperature distributions along x-axis and y-axis are obtained via numerical computation. The computation results coincide with the experimental data given by Harphain and Shambaugh. The distributions of the air velocity and air temperature are introduced into the air drag model of melt blowing. The model prediction of the fiber diameter agrees with the experimental data well.

NUMERICAL SIMULATION OF THE FLOW FIELD IN A THERMAL PLASMA REACTOR

A numerical simulation is presented for a thermal plasma reactor with particle-trajectory model in this paper. Turbulance is considered by using simple SGS model. The governing equations are solved by means of the algorithm of SIMPLER. The calculated results give the velocity and the temperature fields within plasma reactor, and the trajectories of the injected particles.

Numerical Simulation of Tripolar Vortex in Dusty Plasma with Sheared Flow and Sheared Magnetic Field

This article presents a study we have made of one class of coherent structures of the tripolar vortex. Considering the sheared flow and sheared magnetic field which are common in the thermonuclear plasma and space plasma, we have simulated the dynamics of the tripolar vortex. The results show that the tripolar vortex is largely stable in most cases, but a strongly sheared magnetic field will make the structure less stable, and lead it to decays into single vortices with the large space scale. These results are consistent with findings from former research about the dipolar vortex.

Study on optimal design of vertical-shaft mechanical mixer based on numerical simulation of flow field

In the paper the three-dimensional flow fields are numerically simulated in the vertical-shaft mechanical mix tank of a water treatment plant by means of FLUENT software based on the method of Computational Fluid Dynamics (CFD). The influences of design parameters on flow fields and the mixing effect are analyzed. Firstly,the prediction capability of the turbulence model adopted in simulations is evaluated. And then,the mesh independence is checked up. Finally,the flow fields in various dimensionless blade diameters and dimensionless shaft spans are numerically simulated respectively. The results have shown that the numerical simulation method based on CFD is a feasible assistance for the optimal designs of mixers. Moreover,the optimal design of the blade diameter should take into account both the flow field and the power consumption. The optimization of the shaft span is to achieve a relatively even distribution of the flow field without any rupture. With the consideration of an optimal design,the dimensionless blade diameter and dimensionless shaft span should be 0.45 and 0.57 respectively in the case.

Numerical simulation of the dynamic characteristics of flow fields under ice

Atmospheric and oceanic drag are the main environmental forces controlling sea ice drift. Oceanic drag includes the form drag generated by water pressure gradients on the side of ice floes or on ice ridges, and the skin friction generated by viscous flow on the bottom of ice floes. In this study, we carried out a two-dimensional numerical simulation using FLUENT software to investigate the characteristics of dynamic flow under ice with a smooth undersurface. We studied water drag and flow field distribution below the ice under different conditions of ice draft and flow velocity, and the results agreed well with data from laboratory-based physical modeling tests, demonstrating the ability of the numerical model to reproduce the dynamic interactions between sea ice and the flow field. The degree of distortion in the flow field caused by ice increased as the ice draft increased. Vortexes occurred in the wake field of the floe, and the centers of the vortexes moved away from the ice with increasing ice draft. The simulated drag of water on ice showed a clear linear relationship with the square of the flow velocity.

A numerical simulation of unsteady flow in small diameter helical grafts

The application of small diameter arterial grafts is limited due to the fact of relatively poor long-time patency which is caused by thrombosis formation in the short term and intimal hyperplasia(IH) in the medium and long term.Thrombosis,obstructing the flow of blood

NUMERICAL SIMULATION OF UNSTEADY FLOW AROUND A CIRCULAR CYLINDER AT HIGH REYNOLDS NUMBERS

A Lagrangian-Eulerian hybrid scheme to solve unsteady N-S equation in two-dimensional incompressible fluid at high Reynolds numbers is presented in this paper. A random walk is imposed to simulate the viscous diffusion, the vortex-in-cell method is used to obtain the convection velocity, and nascent vortices are created on a cylinder to satisfy the zero-slip condition. The impulsively started flow around a circular cylinder and the separation induced by a pair of incident vortices symmetrically approaching a circular cylinder have been successfully simulated by the hybrid scheme. The impulsively started flow from rest has been computed at Reynolds numbers 3000 and 9500. Comparisons are made with those results of finite-difference method, vortex method and flow visualization. Agreement is good. The particular attention has been paid to the evolutions of flow pattern. A topological analysis has been proposed in the region of the near wake. The bulge, isolated secondary vortex, a pair of secondary vortices, ' forewake phenomenon and other patterns are simulated numerically. The separation induced by a pair of incident vortices approaching a circular cylinder has been investigated by using the same scheme. The rebounding phenomenon of the incident vortex is observed and is attributed to the effect of the secondary vortex. In particular, we have found that a tertiary vortex can be formed near the surface; this phenomenon has been verified by flow visualization reported recently.