Numerical simulation and experiment validation of level-pour direct-chill casting of A390 alloy hollow billets under different feeding schemes

2016 ◽  
Vol 26 (6) ◽  
pp. 1871-1888 ◽  
Author(s):  
Kesheng Zuo ◽  
Haitao Zhang ◽  
Ke Qin ◽  
Jianzhong Cui
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Three Dimensional ◽  
Direct Chill ◽  
Melt Flow ◽  
Content Type ◽  
Primary Si ◽  
Hollow Billet ◽  
Dc Casting ◽  
A390 Alloy

Purpose – The purpose of this paper is to study the effect of feeding scheme on melt flow and temperature field during the steady-state of level-pour direct-chill (DC) casting of A390 alloy hollow billet and optimize the design of feeding scheme. Design/methodology/approach – Melt flow and temperature field are investigated by numerical simulation, which is based on a three-dimensional mathematical model and well verified by experiments. Findings – The numerical results reveal that both melt flow and temperature field are obviously affected by the feeding scheme. The homogeneity of melt flow and temperature field in hollow billet with the feeding scheme of modified four inlets are better than the other feeding schemes. Experimental results show that crack can be eliminated by increasing the number of feeding inlets. The primary Si size appears unaffected while the distribution of primary Si particles is highly affected by the change of feeding scheme. Only with the feeding scheme of modified four inlets can fine and uniformly distributed primary Si particles be achieved. Practical implications – The paper includes implications for the design of feeding scheme in level-pour DC casting of hollow billet for practical use. Originality/value – This paper develops different feeding schemes for level-pour DC casting of hollow billet and optimizes the design of feeding scheme.

Numerical simulation on sprue distributions during cladding casting process

2016 ◽  
Vol 26 (8) ◽  
pp. 2340-2354 ◽  
Author(s):  
Xing Han ◽  
Haitao Zhang ◽  
Bo Shao ◽  
Dongtao Wang ◽  
Longgang Cheng ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Casting Process ◽  
Mathematic Model ◽  
Melt Flow ◽  
Content Type ◽  
Metallurgical Bonding ◽  
Flow Heat ◽  
Simulation Results ◽  
Interface Bonding Strength

Purpose The purpose of this paper is to investigate the influence of sprue distributions on the flow field and temperature field of the cladding casting process and verify the simulation results by experiments. Design/methodology/approach A steady-state mathematic model for the coupling of fluid flow, heat transfer and solidification to describe the process of cladding casting was present. The effect of sprue distributions on melt flow and temperature field was discussed. Based on the numerical simulation results, the cladding billet was prepared successfully. Moreover, the model has been verified against by temperature measurements during the cladding casting process. Findings There is a good agreement between the measured and calculated results. The homogeneity of melt flow determines the formability of cladding billets and circular temperature difference affects the bonding of the two alloys. The AA4045/AA3003 cladding billet with no defects in size of f140/f110 mm was fabricated successfully. The alloy elements diffused across the interface and formed diffusion layer with a thickness of 15 µm. The interface bonding strength is higher than the tensile strength of AA3003, indicating the metallurgical bonding between two alloys. Research limitations/implications The casting parameters are limited to the aluminum alloy cladding billet in size of f140/f110 mm in this paper. Originality/value There are few reports of cladding billet, which are used to prepare condense pipes of automotive engines. The effect of distribution schemes on the cladding casting process is rarely studied.

Numerical Simulation on Process of Flow and Heat Transfer in Upright Magnesium Reducing Furnace

2011 ◽  
Vol 383-390 ◽  
pp. 6657-6662 ◽  
Author(s):  
Jun Xiao Feng ◽  
Qi Bo Cheng ◽  
Si Jing Yu
Keyword(s):  
Heat Transfer ◽  
Numerical Simulation ◽  
Temperature Field ◽  
Flue Gas ◽  
Gas Flow ◽  
Three Dimensional ◽  
Reaction Heat ◽  
Flow And Heat Transfer ◽  
Major Factors ◽  
High Chemical Reaction

Based on the analysis of structural characteristic superiority, the process of combustion, flue gas flow and heat transfer in the upright magnesium reducing furnace, the three dimensional mathematical model is devoloped. And numerical simulation is performed further with the commercial software FLUENT. Finally, the flow and temperature field in furnace and temperature field in reducing pot have been obtained. The results indicate that the upright magnesium reducing furnace has perfect flue gas flow field and temperature field to meet the challenge of the magnesium reducing process; the major factors that affect the magnesium reducing reaction are the low thermal conductivity of slag and the high chemical reaction heat absorption.

Temperature distribution simulations during electron beam freeform fabrication process based on the fully threaded tree

2019 ◽  
Vol 25 (6) ◽  
pp. 989-997
Author(s):  
Yajun Yin ◽  
Wei Duan ◽  
Kai Wu ◽  
Yangdong Li ◽  
Jianxin Zhou ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Electron Beam ◽  
Additive Manufacturing ◽  
Temperature Distribution ◽  
Design Methodology ◽  
Content Type ◽  
Freeform Fabrication ◽  
Simulation Based ◽  
Simulation Results

Purpose The purpose of this study is to simulate the temperature distribution during an electron beam freeform fabrication (EBF3) process based on a fully threaded tree (FTT) technique in various scales and to analyze the temperature variation with time in different regions of the part. Design/methodology/approach This study presented a revised model for the temperature simulation in the EBF3 process. The FTT technique was then adopted as an adaptive grid strategy in the simulation. Based on the simulation results, an analysis regarding the temperature distribution of a circular deposit and substrate was performed. Findings The FTT technique was successfully adopted in the simulation of the temperature field during the EBF3 process. The temperature bands and oscillating temperature curves appeared in the deposit and substrate. Originality/value The FTT technique was introduced into the numerical simulation of an additive manufacturing process. The efficiency of the process was improved, and the FTT technique was convenient for the 3D simulations and multi-pass deposits.

scholarly journals Research on Model Slice and Forming Method of Thin-walled Parts

2021 ◽  
Vol 233 ◽  
pp. 04046
Author(s):  
Changhao Zhang ◽  
Hu Li ◽  
Jianyu Yang ◽  
Huawei Lu ◽  
Peng Su
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Structural Characteristics ◽  
Three Dimensional ◽  
Simulation Method ◽  
Processing Parameters ◽  
Transient Temperature ◽  
Transient Temperature Field ◽  
Thin Walled ◽  
Experimental Processing

According to the structural characteristics of thin-walled parts, a model slicing method is proposed, and its mathematical process is established. The three-dimensional transient temperature field in the process of synchronous powder feeding laser cladding is studied and verified by numerical simulation method, and the thin-walled parts formed by later experimental processing are processed by the results of numerical simulation. Using the simulation results of temperature field as the basis for optimizing the processing parameters, the forming path of thin-walled parts is programmed and optimized, and the experimental verification shows the reliability of this method.

Thermal-stress analysis and calculation of single and dual chip set double-sided circuit board based on three-dimensional finite element algorithm

Circuit World ◽  
2015 ◽  
Vol 41 (2) ◽  
pp. 49-54
Author(s):  
Lan Song ◽  
Yang Zhao ◽  
Yaoming Zhou ◽  
Haifei Xiang
Keyword(s):  
Finite Element ◽  
Temperature Field ◽  
Thermal Stress ◽  
Three Dimensional ◽  
Circuit Board ◽  
Content Type ◽  
Thermal Stress Field ◽  
Dimensional Finite Element ◽  
Three Dimensional Finite Element ◽  
Element Algorithm

Purpose – The purpose of this paper is to analyze and figure out the temperature field and thermal stress field with the calculation model of thermal insulation material and composite material. Design/methodology/approach – The paper adopted the three-dimensional finite element algorithm. Findings – The simulated results showed great shearing strength between the chipset and the printed circuit board. The position of chip exerts great influence on the distribution of temperature field and thermal stress field of circuit board. The reasonable distribution of chip will effectively reduce the temperature extremum and stress extremum of circuit board. Originality/value – The paper analyzes and presents a discussion of the problems relating to the density of electronic packaging. The analysis process and the method of the paper provide essential help in resolving electronic device heat problems.

Solidification Mechanisms in Melt Conditioned Direct Chill (MC-DC) Cast AZ31 Billets

2013 ◽  
Vol 765 ◽  
pp. 291-295 ◽  
Author(s):  
Ming Xu Xia ◽  
A.K. Prasada Rao ◽  
Zhong Yun Fan
Keyword(s):  
Solidification Front ◽  
Casting Process ◽  
Direct Chill ◽  
Melt Flow ◽  
Metallographic Examination ◽  
Dc Casting ◽  
Solidification Mechanism

The solidification mechanism in the melt conditioned direct chill (MC-DC) casting process was investigated by pouring liquid Pb into the sump during the casting process. This preserved the solidification front for subsequent metallographic examination. The results demonstrated that the solidification in the MC-DC casting process was preceded by the sedimentation of rosettes, which were nucleated in the sump and then grew under intensive melt flow.

Simulation and Optimize Design for Deflector Plate of the Vehicle Mounted Vertically Thermal Launched Missile

2012 ◽  
Vol 459 ◽  
pp. 579-583
Author(s):  
Shao Zhen Yu ◽  
Yi Jiang ◽  
Yan Li Ma ◽  
Yan Yan Ma ◽  
Bo Wei Liu
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Simulation Study ◽  
Three Dimensional ◽  
Gas Jet ◽  
Potential Core ◽  
Structured Grid ◽  
Main Factors ◽  
Deflector Plate ◽  
Volume Method

In this dissertation, academic analysis of the influence to deflector plate in gas jet field of a Vehicle-mounted Vertically Thermal Launched missile as well as simulation study. The finite volume method, a fully structured grid, three-dimensional N-S equation is used for the numerical simulation of the process during the missile launching. The two main factors: temperature and forces on the launcher is the standard we test a launching system. The temperature on the position we test will rise with the decreasing length of the deflector. Especially, when the length is near to the potential core, the temperature changed greatly. Also, the angles of the deflector under the same length have less impacted on the temperature field. However, the force on the deflector would be change greater than the temperature with the change of angles

scholarly journals Effects of Heat Treatment and Extrusion on Microstructure and Properties of A390 Alloy Hollow Billet Fabricated via DC Casting

2015 ◽  
Vol 56 (9) ◽  
pp. 1591-1598 ◽  
Author(s):  
Kesheng Zuo ◽  
Haitao Zhang ◽  
Ke Qin ◽  
Xing Han ◽  
Bo Shao ◽  
...  
Keyword(s):  
Heat Treatment ◽  
Microstructure And Properties ◽  
Hollow Billet ◽  
Dc Casting ◽  
A390 Alloy

Three-dimensional numerical simulation of oxide melt flow in Czochralski configuration

2000 ◽  
Vol 216 (1-4) ◽  
pp. 372-388 ◽  
Author(s):  
C.J Jing ◽  
N Imaishi ◽  
T Sato ◽  
Y Miyazawa
Keyword(s):  
Numerical Simulation ◽  
Three Dimensional ◽  
Melt Flow ◽  
Oxide Melt
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