Optimized DISA system parameters of a thin-wall malleable iron pipe casting by numerical simulation

The filling and solidification of a malleable iron pipe casting manufactured by DISA casting mold line with different design parameters were calculated by using software MAGMASOFT. Then the shrinkage porosity was predicted by thermal criterion. Based on the simulation results, the influences of the runner ratio and feeder position on the porosity were discussed. The results show that synchronization of injection can be significantly influenced by the size of downsprue section, and an de-sign structure of DISA gating system was used to solve the problem of flow imbalance in the filling procegs. At the same time, the riser was designed on the hotspot for feeding shrinkage. At last, the optimizated gating system and feeding system were ac-complished to eliminate shrinkage porosity.

Analysis of debris flow control effect and hazard assessment in Xinqiao Gully,Wenchuan M_(s)8.0 earthquake area based on numerical simulation

Xinqiao Gully is located in the area of the 2008 Wenchuan M_(s)8.0 earthquake in Sichuan province,China.Based on the investigation of the 2023"6-26"Xinqiao Gully debris flow event,this study assessed the effectiveness of the debris flow control project and evaluated the debris flow hazards.Through field investigation and numerical simulation methods,the indicators of flow intensity reduction rate and storage capacity fullness were proposed to quantify the effectiveness of the engineering measures in the debris flow event.The simulation results show that the debris flow control project reduced the flow intensity by41.05%to 64.61%.The storage capacity of the dam decreases gradually from upstream to the mouth of the gully,thus effectively intercepting and controlling the debris flow.By evaluating the debris flow of different recurrence intervals,further measures are recommended for managing debris flow events.

Numerical simulation on sand sedimentation and erosion characteristics around HDPE sheet sand barrier under different wind angles

For the safety of railroad operations,sand barriers are utilized to mitigate wind-sand disaster effects.These disasters,characterized by multi-directional wind patterns,result in diverse angles among the barriers.In this study,using numerical simulations,we examined the behavior of High Density Polyethylene(HDPE)sheet sand barriers under different wind angles,focusing on flow field distribution,windproof efficiency,and sedimentation erosion dynamics.This study discovered that at a steady wind speed,airflow velocity varies as the angle between the airflow and the HDPE barrier changes.Specifically,a 90°angle results in the widest low-speed airflow area on the barrier’s downwind side.If the airflow is not perpendicular to the barrier,it prompts a lateral airflow movement which decreases as the angle expands.The windproof efficiency correlates directly with this angle but inversely with the wind’s speed.Notably,with a wind angle of 90°,wind speed drops by 81%.The minimum wind speed is found at 5.1H(the sand barrier height)on the barrier’s downwind side.As the angle grows,the barrier’s windproof efficiency improves,extending its protective reach.Sedimentation is most prominent on the barrier’s downwind side,as the wind angle shifts from 30°to 90°,the sand sedimentation area on the barrier’s downwind side enlarges by 14.8H.As the angle grows,sedimentation intensifies,eventually overtakes the forward erosion and enlarges the sedimentation area.

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.

Gating system optimization of low pressure casting A356 aluminum alloy intake manifold based on numerical simulation

To eliminate the shrinkage porosity in low pressure casting of an A356 aluminum alloy intake manifold casting, numerical simulation on fi lling and solidifi cation processes of the casting was carried out using the ProCAST software. The gating system of the casting is optimized according to the simulation results. Results show that when the gating system consists of only one sprue, the fi lling of the molten metal is not stable; and the casting does not follow the sequence solidifi cation, and many shrinkage porosities are observed through the casting. After the gating system is improved by adding one runner and two in-gates, the fi lling time is prolonged from 4.0 s to 4.5 s, the fi lling of molten metal becomes stable, but this casting does not follow the sequence solidifi cation either. Some shrinkage porosity is also observed in the hot spots of the casting. When the gating system was further improved by adding risers and chill to the hot spots of the casting, the shrinkage porosity defects were eliminated completely. Finally, by using the optimized gating system the A356 aluminum alloy intake manifold casting with integrated shape and smooth surface as well as dense microstructure was successfully produced.

Fluid-solid coupling numerical simulation of charge process in variable-mass thermodynamic system

Abstract： A joint solution model of variabk：-mass flow in two-phase region and fluid-solid coupling heat transfer, concerned about the charge process of variable-mass thermodynamic system, is built up and calculated by the finite element method （FEM）. The results are basically consistent with relative experimental data. The calculated average heat transfer coefficient reaches 1.7~105 W/（m2. K）. When the equal percentage valve is used, the system needs the minimum requirements of valve control, but brings the highest construction cost. With the： decrease of initial steam pressure, the heat transfer intensity also weakens but the steam flow increases. With the initial water filling coefficient increasing or the temperature of steam supply decreasing, the amount of accumulative steam flow increases with the growth of steam pressure. When the pressure of steam supply drops, the steam flow gradient increases during the maximum opening period of control valve, and causes the maximum steam flow to increase.

An Application of the RAMS/FLUENT System on the Multi-Scale Numerical Simulation of the Urban Surface Layer—A Preliminary Study

The Regional Atmospheric Modeling System （RAMS） and the computational fluid dynamics （CFD） codes known as FLUENT are combinatorially applied in a multi-scale numerical simulation of the urban surface layer （USL）. RAMS and FLUENT are combined as a multi-scale numerical modeling system, in which the RAMS simulated data are delivered to the computational model for FLUENT simulation in an offline way. Numerical simulations are performed to present and preliminarily validate the capability of the multi-scale modeling system, and the results show that the modeling system can reasonably provide information on the meteorological elements in an urban area from the urban scale to the city-block scale, especially the details of the turbulent flows within the USL.

Numerical Simulations of Intense Meiyu Rainfall in 1991 over the Changjiang and Huaihe River Valleys by a Regional Climate Model with p-σ Incorporated Coordinate System

Based on the primitive equation model with p- σ incorporated coordinate system originally developed by Qian et al., a one-way nested fine mesh limited area model is developed. This model is nested with ECMWF T42 data to simulate the extra-intensive rainfall event occurring in the Changjiang and Huaihe River valleys in summer of 1991. The results show that the model has certain capacity to fairly reproduce the regional distribution and the movement of the main rainfall belts. Therefore it can be used as a regional climate model to simulate and predict the short-range regional climate changes.

Explosion resistance performance of reinforced concrete box girder coated with polyurea:Model test and numerical simulation

To study the anti-explosion protection effect of polyurea coating on reinforced concrete box girder,two segmental girder specimens were made at a scale of 1:3,numbered as G(without polyurea coating)and PCG(with polyurea coating).The failure characteristics and dynamic responses of the specimens were compared through conducting explosion tests.The reliability of the numerical simulation using LS-DYNA software was verified by the test results.The effects of different scaled distances,reinforcement ratios,concrete strengths,coating thicknesses and ranges of polyurea were studied.The results show that the polyurea coating can effectively enhance the anti-explosion performance of the girder.The top plate of middle chamber in specimen G forms an elliptical penetrating hole,while that in specimen PCG only shows a very slight local dent.The peak vertical displacement and residual displacement of PCG decrease by 74.8% and 73.7%,respectively,compared with those of specimen G.For the TNT explosion with small equivalent,the polyurea coating has a more significant protective effect on reducing the size of fracture.With the increase of TNT equivalent,the protective effect of polyurea on reducing girder displacement becomes more significant.The optimal reinforcement ratio,concrete strength,thickness and range of polyurea coating were also drawn.

Desulfurization characteristics of slaked lime and regulation optimization of circulating fluidized bed flue gas desulfurization process--A combined experimental and numerical simulation study

Circulating fluidized bed flue gas desulfurization(CFB-FGD) process has been widely applied in recent years. However, high cost caused by the use of high-quality slaked lime and difficult operation due to the complex flow field are two issues which have received great attention. Accordingly, a laboratory-scale fluidized bed reactor was constructed to investigate the effects of physical properties and external conditions on desulfurization performance of slaked lime, and the conclusions were tried out in an industrial-scale CFB-FGD tower. After that, a numerical model of the tower was established based on computational particle fluid dynamics(CPFD) and two-film theory. After comparison and validation with actual operation data, the effects of operating parameters on gas-solid distribution and desulfurization characteristics were investigated. The results of experiments and industrial trials showed that the use of slaked lime with a calcium hydroxide content of approximately 80% and particle size greater than 40 μm could significantly reduce the cost of desulfurizer. Simulation results showed that the flow field in the desulfurization tower was skewed under the influence of circulating ash. We obtained optimal operating conditions of 7.5 kg·s^(-1)for the atomized water flow, 70 kg·s^(-1)for circulating ash flow, and 0.56 kg·s^(-1)for slaked lime flow, with desulfurization efficiency reaching 98.19% and the exit flue gas meeting the ultraclean emission and safety requirements. All parameters selected in the simulation were based on engineering examples and had certain application reference significance.

Numerical simulation on the multiphase flow and reoxidation of the molten steel in a two-strand tundish during ladle change

A 3D mathematical model was proposed to investigate the molten steel–slag–air multiphase flow in a two-strand slab continuous casting(CC)tundish during ladle change.The study focused on the exposure of the molten steel and the subsequent reoxidation occurrence.The exposure of the molten steel was calculated using the coupled realizable k–εmodel and volume of fluid(VOF)model.The diffusion of dissolved oxygen was determined by solving the user-defined scalar(UDS)equation.Moreover,the user-defined function(UDF)was used to describe the source term in the UDS equation and determine the oxidation rate and oxidation position.The effect of the refilling speed on the molten steel exposure and dissolved oxygen content was also discussed.Increasing the refilling speed during ladle change reduced the refilling time and the exposure duration of the molten steel.However,the elevated refilling speed enlarged the slag eyes and increased the average dissolved oxygen content within the tundish,thereby exacerbating the reoxidation phenomenon.In addition,the time required for the molten steel with a high dissolved oxygen content to exit the tundish varied with the refilling speed.When the inlet speed was 3.0 m·s^(-1)during ladle change,the molten steel with a high dissolved oxygen content exited the outlet in a short period,reaching a maximum dissolved oxygen content of 0.000525wt%.Conversely,when the inlet speed was 1.8 m·s^(-1),the maximum dissolved oxygen content was 0.000382wt%.The refilling speed during the ladle change process must be appropriately decreased to minimize reoxidation effects and enhance the steel product quality.

In-situ measurement via the flow-through method and numerical simulations for radon exhalation during measurements of the radon exhalation rate

Small-scale measurements of the radon exhalation rate using the flow-through and closed-loop methods were conducted on the surface of a uranium tailing pond to better understand the differences between the two methods.An abnormal radon exhalation behavior was observed,leading to computational fluid dynamics(CFD)-based simulations in which dynamic radon migration in a porous medium and accumulation chamber was considered.Based on the in-situ experimental and numerical simulation results,variations in the radon exhalation rate subject to permeability,flow rate,and insertion depth were quantified and analyzed.The in-situ radon exhalation rates measured using the flow-through method were higher than those measured using the closed-loop method,which could be explained by the negative pressure difference between the inside and outside of the chamber during the measurements.The consistency of the variations in the radon exhalation rate between the experiments and simulations suggests the reliability of CFD-based techniques in obtaining the dynamic evolution of transient radon exhalation rates for diffusion and convection at the porous medium-air interface.The synergistic effects of the three factors(insertion depth,flow rate,and permeability)on the negative pressure difference and measured exhalation rate were quantified,and multivariate regression models were established,with positive correlations in most cases;the exhalation rate decreased with increasing insertion depth at a permeability of 1×10^(−11) m^(2).CFD-based simulations can provide theoretical guidance for improving the flow-through method and thus achieve accurate measurements.

Determination method of mesh size for numerical simulation of blast load in near-ground detonation

In order to improve the overall resilience of the urban infrastructures, it is required to conduct blast resistant design for important building structures in the city. For complex terrain in the city, it is recommended to determine the blast load on the structures via numerical simulation. Since the mesh size of the numerical model highly depends on the explosion scenario, there is no generally applicable approach for the mesh size selection. An efficient method to determine the mesh size of the numerical model of near-ground detonation based on explosion scenarios is proposed in this study. The effect of mesh size on the propagation of blast wave under different explosive weights was studied, and the correlations between the mesh size effect and the charge weight or the scaled distance was described. Based on the principle of the finite element method and Hopkinson-Cranz scaling law, a mesh size measurement unit related to the explosive weight was proposed as the criterion for determining the mesh size in the numerical simulation. Finally, the applicability of the method proposed in this paper was verified by comparing the results from numerical simulation and the explosion tests and was verified in AUTODYN.

Operation optimization of prefabricated light modular radiant heating system:Thermal resistance analysis and numerical study

The utilization of prefabricated light modular radiant heating system has demonstrated significant increases in heat transfer efficiency and energy conservation capabilities.Within prefabricated building construction,this new heating method presents an opportunity for the development of comprehensive facilities.The parameters for evaluating the effectiveness of such a system are the upper surface layer’s heat flux and temperature.In this paper,thermal resistance analysis calculation based on a simplified model for this unique radiant heating system analysis is presented with the heat transfer mechanism’s evaluation.The results obtained from thermal resistance analysis calculation and numerical simulation indicate that the thermal resistance analysis method is highly accurate with temperature discrepancies ranging from 0.44℃ to−0.44℃ and a heat flux discrepancy of less than 7.54%,which can meet the requirements of practical engineering applications,suggesting a foundation for the prefabricated radiant heating system.

Multi-physical fields distribution in billet during helical electromagnetic stirring:A numerical simulation research

Electromagnetic stirring is one of the widely applied techniques to modify the quality of casting billets.Different from conventional rotate stirring,the helical stirring is more professional in assisting multi-dimensional flow of molten metal and eliminating solidification defects.In this study,the single-winding helical stirring(SWHS)was introduced,offering advantages such as smaller volume and lower electromagnetic shielding compared to traditional helical stirring methods.Following a comprehensive numerical simulation,the stirring parameters of SWHS were adjusted to yoke inclination angle of 43°and frequency of 12 Hz.The higher electromagnetic force and flow velocity in drawing direction,as well as the lower temperature gradient induced by the SWHS,are positive factors for homogeneous solidification of billet.The experimental results on Al-8%Si alloy and 0.4%C-1.1%Mn steel demonstrate that compared to rotate stirring,the SWHS process can induce better billet quality and is more effective in accelerating the equiaxed expansion and reducing element segregation.The SWHS process can enhance the equiaxed ratio of the billet by 58.3%and reduce segregation degree of carbon element by 10.97%.Consequently,SWHS holds great promise as a potential approach for improving the quality of continuous casting billets.

Numerical simulation on magnetohydrodynamic power generation channel of scramjet

The reverse magnetohydrodynamic(MHD)energy bypass technology is a promising energy redis⁃tribution technology in the scramjet system,in augmented with a power generation equipment to supply the neces⁃sary long-distance flight airframe power.In this paper,a computational model of the scramjet magnetohydrody⁃namic channel is developed and verified by using the commercial software Fluent.It is found that when the mag⁃netic induction intensity is 1,2,3,4 T,the power generation efficiency is 22.5%,22.3%,22.0%,21.5%,and decreases with the increase of the magnetic induction intensity,and the enthalpy extraction rate is 0.026%,0.1%,0.21%,0.34%,and increases with the increase of the magnetic induction intensity.The deceleration ef⁃fect of electromagnetic action on the airflow in the power channel increases with the increase of magnetic induc⁃tion intensity.The stronger the magnetic field intensity,the more obvious the decreasing effect of fluid Mach num⁃ber in the channel.The power generation efficiency decreases as the magnetic induction intensity increases and the enthalpy extraction rate is reversed.As the local currents gathering at inlet and outlet of the power generation area,total temperature and enthalpy along the flow direction do not vary linearly,and there are maximum and minimum values at inlet and outlet.Increasing the number of electrodes can effectively regulate the percentage of Joule heat dissipation,which can improve the power generation efficiency.

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.

Three-dimensional transient numerical simulation for intake process in the engine intake port-valve-cylinder system

This paper presents a KIVA-3 code based numerical model for three-dimensional transient intake flow in the intake port-valve-cylinder system of internal combustion engine using body-fitted technique, which can be used in numerical study on internal combustion engine with vertical and inclined valves, and has higher calculation precision. A numerical simulation (on the intake process of a two-valve engine with a semi-sphere combustion chamber and a radial intake port) is provided for analysis of the velocity field and pressure field of different plane at different crank angles. The results revealed the formation of the tumble motion, the evolution of flow field parameters and the variation of tumble ratios as important information for the design of engine in-take system.

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 study on the mold strength of magnetic mold casting based on a coupled electromagnetic-structural method

The properties of the magnetic mold in magnetic mold casting directly determine the quality of the final cast parts.In this study,the magnetic mold properties in magnetic mold casting,were studied utilizing a coupled electromagnetic-structural method through numerical simulation.This study investigated key factors including equivalent stress,the distribution of tensile and compressive stresses,and the area ratio of tensile stress.It compared molds made entirely of magnetic materials with those made partially of magnetic materials.Simulation results indicate that as current increases from 4 A to 8 A,both the initial magnetic mold and the material-replaced magnetic mold initially show an increasing trend in equivalent stress,tensile-compressive stress,and the area ratio of tensile stress,peaking at 6 A before declining.After material replacement,the area ratio of tensile stress at 6 A decreases to 19.84%,representing a reduction of 29.72%.Magnetic molds comprising a combination of magnetic and non-magnetic materials exhibit sufficient strength and a reduced area ratio of tensile stress compared to those made entirely from magnetic materials.This study provides valuable insights for optimizing magnetic mold casting processes and offers practical guidance for advancing the application of magnetic molds.