Modeling and simulation of 3D thermal stresses of large-sized castings in solidification processes

When heavy machines and large scaled receiver system of communication equipment are manufactured, it always needs to produce large-sized steel castings, aluminum castings and etc. Some defects of hot cracking by thermal stress often appear during solidification process as these castings are produced, which results in failure of castings. Therefore predicting the effects of technological parameters for production of castings on the thermal stress during solidification process becomes an important means. In this paper, the mathematical models have been established and numerical calculation of temperature fields by using finite difference method (FDM) and then thermal stress fields by using finite element method (FEM) during solidification process of castings have been carried out. The technological parameters of production have been optimized by the results of calculation and the defects of hot cracking have been eliminated. Modeling and simulation of 3D thermal stress during solidification processes of large-sized castings provided a scientific basis, which promoted further development of advanced manufacturing technique.

Numerical Simulation of Transient Thermal Stress Field for Laser Metal Deposition Shaping

To decrease thermal stress during laser metal deposition shaping(LMDS)process,it is of great importance to learn the transient thermal stress distribution regularities.Based on the“element life and death”technique of finite element analy- sis(FEA),a three-dimensional multi-track and multi-layer numerical simulation model for LMDS is developed with ANSYS parametric design language(APDL)for the first time,in which long-edge parallel reciprocating scanning paths is introduced. Through the model,detailed simulations of thermal stress during whole metal cladding process are conducted,the generation and distribution regularities of thermal stress are also discussed in detail.Using the same process parameters,the simulation results show good agreement with the features of samples which fabricated by LMDS.

SIMULATION OF TEMPERATURE AND THERMAL STRESS FIELD IN LASER MILLING PROCESSING

The physical model of temperature field and thermal stress field are established in this paper, on which the numerical simulation with the assuming physical and laser milling parameters have been finished. The laser milling process can be explained.

STUDY ON NUMERICAL SIMULATION OF CASTING THERMAL STRESSES BASED ON FDM

A system for the numerical simulation of 3D temperature and stress fields during casting process was studied, developed and practiced based on finite difference method (FDM) in this paper. An approach where the stress/strain and the heat transfer analysis use the same computational domain was presented, which avoided transferring temperature data between FDM and FEM nodes and elements. A slot-board steel casting was simulated and the calculated results are in agreements with those obtained from practical producing.

Influence of gas flow on thermal field and stress during growth of sapphire single crystal using Kyropoulos method

The professional modeling software package CrysVUn was employed to study the process of a large sapphire single crystal growth using Kyropoulos method. The influence of gas pressure on thermal field, solid-liquid interface shape, gas velocity field and von Mises stress were studied for the first time. It is found that the root of the seed melt when gas pressure equals to one atmosphere or more than one atmosphere, especially during the seeding period, this result is consistent with the experimental observation, and this paper presents three ways to solve this problem. The temperature gradient and stress decreases significantly as the gas pressure increases. The convexity of the solid-liquid interface slightly increases when the gas pressure increases. Numerical analysis was used to optimize the hot zone design.

The Structure of Ore-controlling Strain and Stress Fields in the Shangzhuang Gold Deposit in Shandong Province,China

The Shangzhuang altered-rock type gold ore deposit is located in the middle segment of and controlled by the Wang＇ershan fault zone in the northwestern part of the Jiaodong gold province, China. The deformation evolution, the structure of strain and stress fields and its ore-controlling effect in the Shangzhuang deposit are discussed in this paper. It is revealed that the deformation evolution has mainly undergone four phases： the early ductile deformation, the second NE-striking horizontal simple shear, the third NE-striking compression-shear and the final NW-striking compression. The mineralization happened during the third stage in which the maximum principal stress gradually transited from NE to NW. The 3-D numerical simulations of the stress field show that, on the condition that the maximum principal stress is NE-striking, the fracture development in the fault zone is favored, while when the maximum principal stress is NW-striking, the fault zone is relatively extensional and it is suitable for the influx and emplacement of ore-forming fluids. The compression-shear strain field during the mineralization is characterized by the λ-type structure, the positive flower structure, etc. Orebodies are mostly equidistantly located in the dilatational spaces, which are distributed in the integral compressional circumstances. And the dilatational spaces are developed where the fault attitude changes or shear joint systems develop. In the overall compression-shear stress field, the strain field bears self-similarity at multiple scales, including the orebody, ore deposit and orefield. The selfsimilarity of the structure comprises the subequidistant distribution of fractures at the same scale and the similar shape of the fractures at various scales. Yet, due to the special geological structure, the orebodies are mostly located in the hanging wall in the Shangzhuang deposit, which is different from most deposits in the Jiaodong gold province. Analyses of the ore-controlling stress and strain fields in the deposit provide an important basis for deposit seeking.

Numerical Simulation of the Protective Effect of Complex Boundaries Toward Shock Waves in a 3D Explosive Field

A numerical method is presented that simulates 3D explosive field problems. A code MMIC3D using this method can be used to simulate the propagation and reflected effects of all kinds of rigid boundaries to shock waves produced by an explosive source. These numerical results indicate that the code MMIC3D has the ability in computing cases such as 3D shock waves produced by air explosion, vortex region of the shock wave, the Mach wave, and reflected waves behind rigid boundaries.

Prilimary result of temperature distribution and associated thermal stress in crust in Tianshui, China

The heat flow in crust and the thermal stress generated by the flow play a very important role in earthquake occurrence. Different crustal structure has different effect on heat distribution and associated thermal stress. In all of typical seismogenic crustal structure models, including the bulge of Moho surface, the deep-large fault in the mid-lower crust, low-velocity and high-conductive layer in the middle crust, and the typical crustal structure in mid-upper crust, the thermal stress produced by deep heat disturbance may move up to the mid-upper crest. This leads to upper brittle part of crust break and hence, strong earthquakes. This result is constructive in enhancing our understanding of the role of deep fieat flow in curst in development of earthquake and its generation, as well as the generation mechanism of the shallow flowing fluid.

Quasi-3D Numerical Simulation of Tidal Hydrodynamic Field

Based on the 2D horizontal plane numerical model, a quasi-3D numerical model is established for coastal regions of shallow water. The characteristics of this model are that the velocity profiles;can be obtained at the same time when the equations of the value of difference between the horizontal current velocity and its depth-averaged velocity in the vertical direction are solved and the results obtained are consistent with the results of the 2D, model. The circulating flow in the rectangular area induced by wind is simulated and applied to the tidal flow field of the radial sandbanks in the South Yellow Sea. The computational results from this quasi-3D model are in good agreement with analytical results and observed data. The solution of the finite difference equations has been found to be stable, and the model is simple, effective and practical.

Numerical simulation of the crustal stress field by using data of deep geophysical exploration in the northern part of North China

DSS data of the last twenty years and more in the northern part of North China are further interpreted, and combined with other geological and geophysical data, the crustal model for the 3 D finite element method is built after straticulate crustal structure and elastic mechanics parameters are obtained. Referring to regional tectonic stress field and taking the effect of gravity into account, the paper constrains properly the model boundary and then computes the displacement of each nodal point and the strain and stress of each element by using the program from the 3 D linear elastic finite method. The relationship between the distribution feature of the crustal stress field and seismicity is discussed on the basis of analyzing contour maps of maximum principal compressive stress in the upper, middle and lower crusts.

Determination of the full-field stress and displacement using photoelasticity and sampling moirémethod in a 3D-printed model

The quantitative characterization of the full-field stress and displacement is significant for analyzing the failure and instability of engineering materials.Various optical measurement techniques such as photoelasticity,moiréand digital image correlation methods have been developed to achieve this goal.However,these methods are difficult to incorporate to determine the stress and displacement fields simultaneously because the tested models must contain particles and grating for displacement measurement;however,these elements will disturb the light passing through the tested models using photoelasticity.In this study,by combining photoelasticity and the sampling moirémethod,we developed a method to determine the stress and displacement fields simultaneously in a three-dimensional(3D)-printed photoelastic model with orthogonal grating.Then,the full-field stress was determined by analyzing 10 photoelastic patterns,and the displacement fields were calculated using the sampling moirémethod.The results indicate that the developed method can simultaneously determine the stress and displacement fields.

Evolution of 3D tectonic stress field and fault movement in North China

Based on data of fault movement surveying, we simulate the evolution process of three dimensional stress field in North China by three dimensional finite element method. Evolutional patterns in one-year time scale from 1986 to 1997 have been illustrated and the evolution characteristics of stress field have been analyzed. In comparison with the seismic activity among that time interval in North China, we have primarily discussed the relationship between the evolution of stress field and seismic activity.

Flow Field and Thermal Analysis of the Divertor Target Plate for HL-2A Tokamak

In the initial phase of the physics experiment, the double-null divertor plates used consist of graphite armor tiles, Mo-alloy intermediate layers and Cu-alloy coolant tubes. In the later operating phase, tungsten will be used as armor tiles. A multi-physical field numerical analysis method is used in this paper. Its analysis model reflects more realistically the real divertor structure than other models. Two-dimensional （2D） and three-dimensional （3D） fluid flow field, temperature distribution and thermal stress analyses of the divertor plates are carried out by the ANSYS code. During the physics experimental phase with a heat flux of 1 MW/m2, a coolant velocity of 5.48 m/s, and a thermal stress of 750 kg/cm2, the graphite armor tiles successfully meet the requirements of temperature, thermal stress and sputtering erosion. The tungsten armor will be considered as a second candidate. The result of simulation can be used for upgrading the design parameters of the HL-2A poloidal divertor.

Finite Element Modeling in Drilling of Nimonic C-263 Alloy Using Deform-3D

The paper proposes a simulated 3D Finite Element Model(FEM)for drilling of Nickel based super alloy known as Nimonic C-263.The Lagrangian finite element model-based simulations were performed to determine the thrust force,temperature generation,effective stress,and effective strain.The simulations were performed according to the L27 orthogonal array.A perfect plastic work piece was assumed,and the shape is considered to be cylindrical.The spindle speed,feed rate,and point angle were considered as the input parameters.The work piece was modeled by Johnson-Cook(JC)material model and tungsten carbide(WC)was chosen as the drill bit and the body was assumed to be rigid.The demonstrative results of the thrust force and the temperature at drill bit cutting edge were substantiated with the simulated results and a percentage error was observed within 10%.Further,simulated results of effective stress and strain were also observed.

Nonlinear Switching Transient Field Simulation of Cable Joint without Residual Charge

The analysis of the impulse voltage on the internal electric field of the cable joint plays a key role in studying the breakdown of the joint. Based on the finite element method, a three-dimensional electromagnetic field simulation model of the cable joint is established in this paper. Simulation results show that the voltage at the head of the cable joint reaches about twice the impulse voltage. The increase of the conductivity of semi-conductive material also leads to the increase of electric field intensity. Then, several points and curves at different positions are selected for further analysis in this paper. Among them, the electric field distortion at the edge of the high voltage shield is the most serious and the electric field in the air gap is the least.

Three-dimensional Monte Carlo simulation of bulk fin field effect transistor

In this paper, we investigate the performance of the bulk fin field effect transistor （FinFET） through a three- dimensional （3D） full band Monte Carlo simulator with quantum correction. Several scattering mechanisms, such as the acoustic and optical phonon scattering, the ionized impurity scattering, the impact ionization scattering and the surface roughness scattering are considered in our simulator. The effects of the substrate bias and the surface roughness scattering near the Si/SiO2 interface on the performance of bulk FinFET are mainly discussed in our work. Our results show that the on-current of bulk FinFET is sensitive to the surface roughness and that we can reduce the substrate leakage current by modulating the substrate bias voltage.

热循环下铝/钢连续驱动摩擦焊接接头应力应变分析

利用ABAQUS有限元软件,建立了一个新的连续驱动摩擦焊接头热-力耦合过程的数值模型,分析了试验过程接头温度场、应力应变分布规律,通过与实际试验结果的对比,验证模型的准确性。得出如下结论:热循环过程中,冷却及低温保温过程是热应力最大的阶段;接头颈缩形貌和产生位置与试验结果吻合较好,颈缩位置与实际试验相对误差为6%,颈缩现象的本质是铝在自由膨胀收缩时应力超过强度极限产生的塑性变形。在拉伸断口观察到解理断裂圆环,其位置、宽度与模拟结果的应变集中区域吻合度高。该模型较准确的模拟了连续驱动摩擦焊接头的热-力耦合过程,为实际生产和工艺优化提供了有力支持。

跳跃运动中不同护膝条件下膝关节半月板应力场的数值研究

目的 采用数值模拟方法,建立人体膝关节肌骨系统生物力学模型,并将人体动力学模型模拟跳跃运动时所获得的运动学和动力学信息作为模型驱动数据,进而分析不同热力耦合护膝条件下膝关节半月板的应力场分布特征。方法 基于受试者CT与MRI断层扫描图像,构建包括骨、关节软骨、半月板、韧带和膝关节外围软组织的较真实人体膝关节模型,依据跳跃运动全周期分析选择蓄力起跳、落地冲击两个半月板损伤风险较大的位姿步态进行模拟,分析4种不同热力耦合护膝条件下膝关节半月板的应力场特征,讨论半月板峰值应力及其应力集中区域的变化,探究半月板损伤以及佩戴护膝的防护功效和力学依据。结果 膝关节内侧半月板前角是应力集中的易受损区域;在热力场耦合护膝条件下,内侧半月板应力集中区域由其狭长且薄弱的前角转移至其较为宽厚的中部,且峰值应力显著降低;内、外侧半月板的峰值应力接近,表明两者共同承担外载,且半月板应力集中区域面积减小。结论 热力场耦合护膝对于膝关节半月板的损伤具有良好防护作用。数值模拟研究结果可以为热力多功能护膝的设计提供理论支撑和技术指导。

金属件熔融堆积3D打印过程热应力场数值模拟

针对熔融堆积3D打印过程中由于热应力场变化导致成形金属件出现翘曲变形的问题,建立了单层铋锡合金件熔融堆积3D打印成形过程的数值分析模型,研究了不同成形路径和堆积速度下热应力场的分布和变化规律,及其对制件翘曲变形的影响。研究结果表明:采用沿短边的成形路径以及提高堆积速度,可以显著降低成形过程中的热应力及其波动性变化,从而减小制件翘曲变形量。在与模拟过程相同的参数条件下,利用自行搭建的金属件熔融堆积3D打印成形实验平台进行了单层铋锡合金试样成形试验对比研究,试验结果与模拟结果基本吻合。

ABS塑料3D打印过程中热应力耦合场分析与优化

随着3D打印技术的快速发展,针对ABS材料进行细致分析、计算方面的研究报道逐渐增多。通过ANSYS中APDL语言编写命令流、建立模型、划分网格、施加载荷、加载边界条件、模拟计算,对ABS材料进行热应力耦合场分析,探讨了喷头温度T_1、成形室温度T2和打印速度V这3个打印参数对试样热应力耦合场的影响,最后进行打印实验,最优化结果为喷头温度T_1=200℃、成型室温度T_2=90℃、打印速度V=30 mm/s。利用这种方法可以进行PP、PVC、PEEK等多种材料的打印成型,也可以进行相关金属、非金属材料的分析与打印设置,拓展了设备使用的领域,也为其它同类型设备或稍旧设备的进一步改造使用提供了借鉴。