A356铝合金半固态浆料电磁搅拌法制备过程的数值模拟

建立电磁搅拌法制备A356铝合金半固态浆料过程的电磁场、温度场和流体力学场多场耦合的二维数值模型,采用Powerlaw cut-off(PLCO)半固态模型来描述铝合金浆料的流场,并利用有限元软件ANSYS和编程软件INTEL FORTRAN相结合对电磁场、温度场和流场耦合模拟,研究多场搅拌参数对电磁场、温度场和流场的影响规律。模拟结果表明,搅拌频率和搅拌电流增加时会使电磁场增大且分布不均匀,从而造成浆料流速迅速增大并且分布不均匀。进一步获得电磁搅拌法制备A356铝合金半固态浆料的合理搅拌参数。在所研制的试验装置上验证了数值模拟的可靠性。     

超声功率对半连续铸造7050铝合金晶粒细化的影响

在7050铝合金半连续铸造过程中引入超声场,研究了超声功率对铸锭凝固组织的影响规律,并探讨了超声细化晶粒的机理。结果表明:在半连续铸造过程中引入超声场后,7050铝合金的凝固组织晶粒明显细化,这主要是由于超声波在铝合金熔体中产生的空化效应和声流效应的影响,并且随着超声功率的提高,合金晶粒细化效果更好。     

相场法模拟枝晶生长

基于Tong提出的耦合流场、温度场、噪音场的相场模型,发展了一个单相场控制的多个晶粒生长模型,对对流作用下的枝晶的非对称生长进行了模拟研究,考虑了枝晶的择优生长方向,应用该模型模拟了纯金属镍单枝晶和多枝晶在流体作用下的生长规律。模拟结果表明。金属液对流对枝晶生长形貌产生重要的影响,该模型能够较真实地再现凝固过程的枝晶生长过程。     

超声振动对7050铝合金铸锭宏观偏析作用规律的实验研究

分别采用不同的施振功率、施振温度、冷却方式研究超声振动作用于7050铝合金凝固过程对铸锭宏观偏析的影响规律.通过实验分析得出超声振动产生的空化效应和声流效应对熔体凝固过程起主要作用,合理的超声工艺和冷却方式均能弱化偏析,不同的冷却条件下,超声处理的最佳功率值不同.     

基于多物理场耦合的高温掺合阀温度场数值模拟研究

为了研究柱塞式高温掺合阀在实际生产中流体域内温度场、速度场、压力场及阀耦合温度场的分布规律,分别采用理论计算方法和基于ANSYS的有限元方法对实际生产工况条件下该阀的流场、温度场进行耦合计算。给出了理论计算过程,为模拟分析提供依据,给出了流体域内温度场、速度场、压力场及阀耦合温度场的计算过程和结果。结果表明:阀内流体域分布中速度场分布与温度场分布整体吻合,态势良好;热流出口段窗口处温度梯度较大,且由于热流段流速较快,耦合过程中有一定射流现象;热流入口处沿径向温度梯度较大,说明隔热件发挥作用,隔热效果较为明显。     

铸件和铸型间界面传热系数的试验研究

在铸造凝固过程的数值模拟中,铸件/铸型间的界面传热系数是非常关键的一个参数.为提高数值模拟精度,文中采用铝合金铸件设计了金属型铸造试验,考虑了铸型厚度对结果的影响,使用特制的热电偶采集了铸件内部不同位置的温度值.以此实测的温度场数据为基础,结合数值模拟技术和界面传热系数“反问题”的求法,得到界面传热系数与时间的函数关系.结果表明:铸型厚度不同会影响铸件铸型间的热流和界面传热系数的变化规律,且界面传热系数在铸件冷却中并非常数,随着凝固过程的继续而减小.最后将所得界面传热系数用于凝固过程的温度场模拟,与试验结果进行了对比分析,得到了合理的分布,说明此界面传热系数测定方法可行.     

计及外流场的子午线轮胎温度场建模方法

为了准确模拟轮胎使用过程中温度场分布情况,提出了一种计及外流场的子午线轮胎温度场建模方法。以某205/55R16型轿车子午线轮胎为研究对象,使用ABAQUS以及ANSYS软件建立轮胎自由滚动力学模型以及轮胎温度场模型,并通过轮胎测温试验验证了仿真模型的可靠性。以热对流、热辐射、热传导3个方面考虑轮胎温度场分布,同时考虑了轮胎实际运行中外部流场的影响。结果表明,新的轮胎温度场建模方法能够更加合理准确的模拟轮胎内部以及外部的温度场与流场分布,对于轮胎性能研究有着十分重要的意义。     

基于Fluent的重力铸造充型凝固过程数值模拟研究

拉伸试棒广泛应用于新材料、新工艺的开发,而标准拉伸试棒铸造模具体积大,造成材料的浪费;型腔截面变化复杂,充型过程中会产生飞溅,在铝合金铸造时容易产生冷隔、浇不足和缩松等缺陷。针对这一情况,设计了一种体积小、截面简单的模具,并用Fluent软件对A357铝合金重力铸造工艺进行了模拟,研究温度场和流场的变化规律,实现充型过程热流耦合和凝固过程的温度场计算,并预测铸件质量。研究结果表明,新模具充型良好,速度平稳,凝固时试棒位置能够有效补缩,消除了缩松缺陷。     

低频超声透皮给药过程流场影响分析

针对低频超声透皮给药过程中声场和流场的促渗机理问题,基于压电方程、声压方程以及湍流k-ε模型,利用COMSOL有限元软件建立了其声-压电-流耦合仿真计算模型。通过理论分析和Franz体外透皮实验分别获得了给药系统中的声场与流场的大小及分布,以及体外实验的超声促渗后的渗透量。仿真计算与实验结果表明:离体皮肤在超声作用下渗透量更大,皮肤上产生更多褶皱与空化穴,这说明存在空化效应与交变载荷,而后者可能是流场流动或涡流引起的;药液中流场沿超声换能器的辐射面下方流动到辐射面侧面,形成搅拌作用,且辐射面正下方的流速最大,当输入电功率为5.5 W时,可达0.55m/s,皮肤上方伴有较强涡流;流场在超声促渗中起搅拌与扩张皮肤通道的作用,对促渗起辅助作用。     

利用CAE技术分析改进铝合金支架压铸工艺

本文基于CAE技术对铝合金汽车支架压铸件工业进行探究与分析，并预测可能产生的铸造缺陷，以此得出零件成型的温度场分布与铝合金逐渐凝固温度、时间的关系。在无水冷和有水冷两套方案中，对各部位节点进行选择，对不同节点凝固中所存在的温度变化规律进行选择。结果显示：在无水冷增设方案中，铝合金汽车支架压铸件会产生混乱的凝固顺序，且出现不合理的温度梯度分布，铸件成型过程极易出现铸造缺陷；在有水冷增设方案中，提高了铸件各节点冷却速度，并保持适宜的凝固顺序，明显降低了铸造缺陷。     

Effect of Oscillation Parameters to Flow Field in the Pool during the Oscillating Twin-Roll Strip Casting Process

During the oscillating twin?roll strip casting process, the quality of final products is directly influenced by the flow field distribution of molten metal in the pool. The variation in the flow field is caused by oscillating roller benefits, for homogeneous distribution of strip impurity, and decreasing the grain size. Thus, the quality of the strip could be improved. A numerical model was developed using the multiphase flow technology, coupled with heat transfer, fluid flow, solidification, and oscillation. Furthermore, a transient algorithm was adopted for simulating the oscillating twin?roll strip casting process of AlSi9Cu3 and 3104 aluminum alloy. This paper focuses on the flow distribution in the pool, in comparison with the traditional vertical twin?roll strip casting process, while the amplitude or frequency is chang?ing with the definite value of casting velocity, roller diameter, nozzle angle, and the strip thickness. Consequently, the conclusions were experimentally validated by oscillating twin?roll 3104 aluminum alloy strip casting. Vibrating casting technology can change the flow field in the pool by vibration, which can improve the quality of the strip core.     

Thermoelastic instability in planar solidification

A linear perturbation method is used to examine the stability of a unidirectional solidification problem in which a liquid, initially at the melting temperature, becomes solidified by heat transfer across a pressure-dependent thermal contact resistance to a plane mold. The contact pressure will be influenced by thermal distortion in response to the instantaneous temperature field in the solidified shell. The heat transfer and thermal stress problems are therefore coupled through the boundary conditions.

The temperature and stress fields are assumed to consist of a unidirectional component and a small spatially-sinusoidal perturbation which can vary with time. Analysis of the thermoelastic problem for the solidified shell leads to an ordinary differential equation relating the perturbation in heat flux at the mold/casting interface and the corresponding perturbation in contact pressure. A second equation relating the same two variables is obtained by linear perturbation of the relation for heat conduction across the thermal contact resistance. These are then reduced to a single equation which is solved numerically. The results show that a small initial perturbation will grow substantially during the solidification process if the thermal contact resistance is very sensitive to pressure.     

Theoretical and experimental study of microstructures and weld pool geometry during GTAW of 304 stainless steel

In this work, temperature field and weld pool geometry during gas tungsten arc welding of 304 stainless steel are predicted by solving the governing equations of heat transfer and fluid flow under quasi-steady state conditions. The model is based on numerical solution of the equations of conservation of mass, momentum, and energy in the weld pool. Weld pool geometry, weld thermal cycles, and various solidification parameters are then calculated by means of the model predictions. The model considers the effects of various process parameters including welding speed and heat input. It is found that the weld pool geometry, predicted by the proposed model, is in reasonable agreement with the corresponding experimentally measured ones. In addition, the solidification behavior of the weld pool can be predicted properly by the model predictions.     

声学法炉内温度场与速度场协同测量方法研究

实时监测炉内燃烧温度场和烟气速度场是保证锅炉安全、经济运行的重要手段,声学法测物理场被认为是一种非侵入性和有效的测量方法。本文提出了一种基于声波法的炉内温度场和烟气速度场的协同测量新方法,建立了基于径向基函数的多物理场重建模型,采用Tikhonov正则化算法求解不适定问题,同时考虑了声波的折射效应对物理场的重建影响。采用典型的炉内物理场模型进行了数值模拟,模拟结果表明,本文方法能够很好的协同重建温度场和速度场。当考虑声线弯曲时能够显著提高各物理场的重建质量。算法具有较好的适应性和良好的抗噪性能,重建精度较高,标准均方根误差在10%以下。模拟实验平均计算时间为31.4 s,可保证炉内声学测量的实时性。声学法协同测量多物理场可为优化炉膛燃烧过程提供依据。     

Heat transfer characteristics in latent heat storage system using paraffin wax

An energy storage system has been designed to study the heat transfer characteristics of paraffin wax during melting and solidification processes in a vertical annulus energy storage system. In the experimental study, three important issues are focused. The first one is temperature distribution in the phase change material (PCM) during the phase change processes. The second one is the thermal characteristics of the paraffin wax, which includes total melting and total solidification times, the nature of heat transfer phenomena in melted and solidified PCM and the effect of Reynolds number as inlet heat transfer fluid (HTF) conditions on the heat transfer parameters. The final one is to calculate heat transfer coefficient and effectiveness during solidification process. The experimental results proved that the PCM melts and solidifies congruently, and the melting front moved from the top to the bottom of the PCM container whereas the solidification front moved from bottom to the top along the axial distances in the PCM container. Experiment has been performed for different water flow rates at constant inlet temperature of heat transfer fluid for recovery and use of heat. Time-based variations of the temperature distributions were explained from the results of observations of melting and solidification curves. Charging and discharging processes were carried out. Heat transfer characteristics were studied.     

Modeling of heat transfer and fluid flow during gas tungsten arc welding of commercial pure aluminum

In the present study, the temperature and the velocity fields during gas tungsten arc welding of commercial pure aluminum were simulated using the solution of the equations of conversation of mass, energy and momentum in three dimensions and under steady-state heat transfer and fluid flow conditions. Then, by means of the prediction of temperature and velocity distributions, the weld pool geometry, weld thermal cycles and various solidification parameters were calculated. To verify the modeling results, welding experiments were conducted on two samples with different thicknesses and the geometry of the weld pool was measured. It is found that there is a good agreement between the predicted and the measured results. In addition, dimensional analysis was employed to understand the importance of heat transfer by convection and the roles of various driving forces in the weld pool. It is observed that the molten metal convection strongly affects on the weld pool geometry. Also the predictions make it possible to estimate the morphology and the scale of the solidified structure through solidification parameter (G/R). The result show that as the net heat input increases, the importance of convection becomes higher and the value of G/R at the weld pool centerline increases.     

新型铝硅基铸造壳体凝固成形研究

新型铝合金材料用于薄壁壳体铸件制备,通过向ZL101A合金中增添微量Ni元素,基于ProCAST铸造仿真软件设计液压泵壳体低压铸造工艺,数值模拟铸件不同部位固相出现时间,并预测铸件凝固过程中缩孔缩松现象。实际生产铝合金薄壁壳体铸件,并对壳体棒料进行高温压缩实验,利用结构变形机理以及微观组织特点分析铸件凝固成形机理。分析合理的浇注温度以及热处理工艺,能够对壳体铸件缩孔缩松现象进行有效控制,保证改进铝硅合金薄壁壳体铸件质量。     

Experimental study on acoustic vector tomography of 2-D flow field in an experiment-scale furnace

An experiment study is performed on acoustic measurement of 2-D dynamic fields in a cold experimental scale furnace. By the acoustic method, the velocity field is restored with the vector tomography from the reciprocal acoustic travel time data measured. Regarding the measuring system, piezoelectric speakers and pickups are used as transmitters and receivers, which can stimulate powerful acoustic signal resource and receive the acoustic signal stimulated from long distance respectively. A high-pass digital FIR filter is designed for the signal filtering, and the signal correlation analysis by correlation coefficient is performed to obtain accurate acoustic transit time data from the filtered simulated and received acoustic signals. In the experiments, two different cases are tested, respectively symmetric and asymmetric flow fields. To validate the flow field recovered by the acoustic method, under the same conditions, the symmetric velocity field is measured by a hot-wire anemometer at some points and simulated with CFD software, and the asymmetrical velocity field is simulated. It is proved that the flow fields recovered by the acoustic method are reasonable and reliable. As a whole, from the experiment results, the acoustic measuring system and method developed in this paper is applicable in measuring the 2-D flow field in a cold experimental set-up and similarly in cold large-scale industrial furnaces. Additionally, the extension of the method to hot furnaces is discussed too.