Numerical Simulation on Influence of Water-Cooled Stool in the Process of Unidirectional Solidification

2014 ◽  
Vol 936 ◽  
pp. 1317-1322
Author(s):  
Xiao Dong Li ◽  
Ming Gang Shen ◽  
Chao Wu
Keyword(s):  
Numerical Simulation ◽  
Cooling System ◽  
Solidification Process ◽  
Longitudinal Direction ◽  
Algebraic Model ◽  
Unidirectional Solidification ◽  
Air Gap ◽  
Temperature Fields ◽  
Element Analysis ◽  
Solidification Temperature

To strengthen the bottom cooling is one of the key technologies of directionally solidified ingot process. Stool cooling scheme has a significant impact on the solidification process of the ingot. The study optimizes chassis cooling scheme according to the air gap between the ingot and the stool. With multiple sets of cooling system, water-cooled stool makes the basal water cooling adapt to air gap distribution through subregional cooling of different intensity control, and be uniform with it in the longitudinal direction solidification. The paper establishes mathematical model of unidirectional solidified ingot on temperature field of conventional water-cooled stool and improved one respectively. By the aid of finite element analysis method, numerical simulation of 45t ingot with algebraic model is carried out. In order to optimize parameters of ingot unidirectional solidification, temperature fields influenced by conventional water-cooled stool and improved one in the process of unidirectional solidification are simulated. The numerical results show that the optimized chassis cooling can result in the ingot in a longitudinal uniform solidification. The numerical simulation results can provide important reference for the optimization of unidirectional solidification process.

Computer Simulation of Filling Process and Temperature Distribution of Oil Pump Cover in Solidification Process

2013 ◽  
Vol 423-426 ◽  
pp. 1894-1897
Author(s):  
Han Wu Liu ◽  
Lian Dong Huang ◽  
Shun Qin Fan ◽  
Bo Hu
Keyword(s):  
Wall Thickness ◽  
Thermal Equilibrium ◽  
Cooling System ◽  
Die Casting ◽  
Solidification Process ◽  
Equilibrium Temperature ◽  
Forming Process ◽  
Element Analysis ◽  
Casting Mold ◽  
Oil Pump

Oil pump cover, as a part of the oil pump, is generally formed by adopting aluminum die casting molding, and required for good internal and external quality. In order to improve the oil pump cover forming quality, the paper first simulates the thermal equilibrium of die-casting mold in the forming process by finite element analysis, and obtains the temperature curves when mold works for 10 consecutive cycles, and determines that the thermal equilibrium temperature of die-casting mold is 260 °C. And then, based on the simulation results of filling and solidification in the forming process by ProCAST software, the shrinkage and cavity appear in the larger wall thickness of the casting. Meanwhile, by simulating the die-casting processes of the oil pump at different pouring temperatures, there are the least of shrinkage and cavity when the pouring temperature setting 640 °C. The results show that: it can take some methods to achieve the progressive solidification, and can reduce or eliminate the possible shrinkage and cavity, such as shortening the distance between sprue, runner and inner runner and die casting to reduce the casting heat loss, or adding cooling system to accelerate the cooling rate in the larger wall thickness of the casting. This analysis provides theoretical basis for the actual casting production of oil pump covers.

The Studies on Numerical Simulation of Unidirectional Solidification Process in 23t Steel Ingot

2012 ◽  
Vol 502 ◽  
pp. 46-50
Author(s):  
Guang Wu Ao ◽  
Ming Gang Shen ◽  
Zhen Shan Zhang ◽  
Li Li Hong
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Temperature Distribution ◽  
Steel Ingot ◽  
Side Wall ◽  
Solidification Process ◽  
Unidirectional Solidification ◽  
Finite Element Software ◽  
Solidification Processes

In this paper, by using the commercial finite-element software of ProCAST, unidirectional solidification processes in 23t steel ingot were simulated. Emphasis is placed on analysis of required time for complete solidification of steel ingot and temperature distribution about ingot and side wall during the solidification process. By comparing simulation values and measured values of side wall during the solidification process, the simulated results conclusively demonstrate that our developed model is feasible and valuable.

Optimal Design of Dynamic Secondary Cooling of Continuous Casting

2012 ◽  
Vol 472-475 ◽  
pp. 1907-1910
Author(s):  
Yi Wang ◽  
Xin Jian Ma
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Finite Element ◽  
Continuous Casting ◽  
Cooling System ◽  
Solidification Process ◽  
Element Model ◽  
Secondary Cooling ◽  
The Mathematical Model ◽  
The Finite Element Model

Numerical simulation of the secondary cooling is applied to the design of continuous casting. The mathematical model for solidification process of the strand under air-mist was established and calculated with the finite element model. The model is used to calculate the feasible operating range of the continuous casting machines. The dynamic secondary cooling system has been analyzed with consideration of the thermo mechanical principles and numerical model. The adequacy of the model has been confirmed with experimental results.

Finite Element Analysis of the Surface Settlement Induced by the Shield Tunnel Construction

2014 ◽  
Vol 501-504 ◽  
pp. 111-114
Author(s):  
Ling Xia Gao ◽  
Xiang Jun Yang ◽  
Li Kun Qin
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Three Dimensional ◽  
Longitudinal Direction ◽  
Element Model ◽  
Surface Settlement ◽  
Shield Tunnel ◽  
Empirical Formulas ◽  
Element Analysis ◽  
Polynomial Expression

Three-dimensional non-linearity finite element model of shield tunnel was established on basis of the Z1 line of Tianjin subway. And then it was applied to simulate construction process of shield tunnel. Surface settlement of the tunnel during the construction was obtained. The settlement data of transverse and longitudinal direction from numerical simulation were fitted through a polynomial expression. Then a contrastive analysis of curves from numerical simulation and matching formulae were made. The result shows that it is feasible to utilize the empirical formulas like Pecks to predict surface settlement in Tianjin caused by shield construction.

Numerical Simulation of the Cooling Process of the Blast Furnace Slag Fiber

2014 ◽  
Vol 934 ◽  
pp. 223-229
Author(s):  
Wei Zhang ◽  
Xu Wang ◽  
Hong Wei Xing
Keyword(s):  
Numerical Simulation ◽  
Blast Furnace ◽  
Blast Furnace Slag ◽  
Solidification Process ◽  
Simulation Software ◽  
Diameter Ratio ◽  
Solidification Time ◽  
Temperature Fields ◽  
Cooling Process ◽  
Furnace Slag

The cooling process of the blast furnace slag fibers was simulated and calculated by the numerical simulation software. The different length-diameter ratio fibers for 100:1 and 1000:1 were chosen and the temperature fields of the fibers cooling process under the different conditions were analyzed. The results showed that the single fiber’s solidification has begun at 0.1s, the fiber forms the whole shell on its surface at 0.9s, and the center of the fiber become solid at about 1.5s. Multi-fibers cooling process is different from the single fiber and the solidification time obviously become longer. 3-fibers’ solidification performs began at about 0.1s, and the whole solidification process needs about 5s.

scholarly journals Die Casting Die Design and Process Optimization of Aluminum Alloy Gearbox Shell

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3999
Author(s):  
Mingyu Huang ◽  
Qian Zhou ◽  
Junyou Wang ◽  
Shihua Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Cooling System ◽  
Structural Characteristics ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Die Design ◽  
Production Cycle ◽  
Gating System

Taking an aluminum alloy gearbox of an automobile as an example, according to its structural characteristics, the parting surface was determined, and the initial gating system was designed by using 3D modeling software UG. Based on Magmasoft software, the numerical simulation of the filling and solidification process was carried out to determine the best gating system scheme. The cooling system and core pulling structure were designed, and the parameter design process of the aluminum alloy gearbox shell in the die-casting process was introduced. Aiming at the leakage problem of the gearbox shell in the bench and road test after assembly, the cause was found through numerical simulation and industrial CT analysis, and the problem was solved by adding high-pressure point cooling at the corresponding position of the leakage, and the correctness of the optimization was verified. It provides an effective method for the die-casting production of the transmission housing and the analysis and solution of product defects, which improves the product quality and shortens the production cycle.

Rubber Composition–Properties Relationships during Tire Numerical Simulation and Design Optimization

2017 ◽  
Vol 45 (1) ◽  
pp. 71-84 ◽  
Author(s):  
Alexey Mazin ◽  
Alexander Kapustin ◽  
Mikhail Soloviev ◽  
Alexander Karanets
Keyword(s):  
Numerical Simulation ◽  
Design Optimization ◽  
Strain Tensor ◽  
General Purpose ◽  
Orthogonal Functions ◽  
Element Analysis ◽  
Time Investment ◽  
Footprint Analysis ◽  
Composition Properties ◽  
Nonlinear Elastic

ABSTRACT Numerical simulation based on finite element analysis is now widely used during the design optimization of tires, thereby drastically reducing the time investment in the design process and improving tire performance because it is obtained from the optimized solution. Rubber material models that are used in numerical calculations of stress–strain distributions are nonlinear and may include several parameters. The relations of these parameters with rubber formulations are usually unknown, so the designer has no information on whether the optimal set of parameters is reachable by the rubber technological possibilities. The aim of this work was to develop such relations. The most common approach to derive the equation of the state of rubber is based on the expansion of the strain energy in a series of invariants of the strain tensor. Here, we show that this approach has several drawbacks, one of which is problems that arise when trying to build on its basis the quantitative relations between the rubber composition and its properties. An alternative is to use a series expansion in orthogonal functions, thereby ensuring the linear independence of the coefficients of elasticity in evaluation of the experimental data and the possibility of constructing continuous maps of “the composition to the property.” In the case of orthogonal Legendre polynomials, the technique for constructing such maps is considered, and a set of empirical functions is proposed to adequately describe the dependence of the parameters of nonlinear elastic properties of general-purpose rubbers on the content of the main ingredients. The calculated sets of parameters were used in numerical tire simulations including static loading, footprint analysis, braking/acceleration, and cornering and also in design optimization procedures.

scholarly journals Optimization of Air Gap Length and Capacitive Auxiliary Winding in Three-Phase Induction Motors Based on a Genetic Algorithm

Energies ◽  
2021 ◽  
Vol 14 (15) ◽  
pp. 4407
Author(s):  
Mbika Muteba
Keyword(s):  
Genetic Algorithm ◽  
Design Process ◽  
Power Factor ◽  
High Speed ◽  
High Efficiency ◽  
Air Gap ◽  
Element Analysis ◽  
Three Phase ◽  
High Torque ◽  
Cage Induction Motor

There is a necessity to design a three-phase squirrel cage induction motor (SCIM) for high-speed applications with a larger air gap length in order to limit the distortion of air gap flux density, the thermal expansion of stator and rotor teeth, centrifugal forces, and the magnetic pull. To that effect, a larger air gap length lowers the power factor, efficiency, and torque density of a three-phase SCIM. This should inform motor design engineers to take special care during the design process of a three-phase SCIM by selecting an air gap length that will provide optimal performance. This paper presents an approach that would assist with the selection of an optimal air gap length (OAL) and optimal capacitive auxiliary stator winding (OCASW) configuration for a high torque per ampere (TPA) three-phase SCIM. A genetic algorithm (GA) assisted by finite element analysis (FEA) is used in the design process to determine the OAL and OCASW required to obtain a high torque per ampere without compromising the merit of achieving an excellent power factor and high efficiency for a three-phase SCIM. The performance of the optimized three-phase SCIM is compared to unoptimized machines. The results obtained from FEA are validated through experimental measurements. Owing to the penalty functions related to the value of objective and constraint functions introduced in the genetic algorithm model, both the FEA and experimental results provide evidence that an enhanced torque per ampere three-phase SCIM can be realized for a large OAL and OCASW with high efficiency and an excellent power factor in different working conditions.

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