Two‐phase thermo‐mechanical and macrosegregation modelling of binary alloys solidification with emphasis on the secondary cooling stage of steel slab continuous casting processes

As an approach towards a better modelling of solidification problems, we introduce a thermo‐mechanical and macrosegregation model that considers a solidifying alloy as a binary mixture made of a liquid and a solid phase. Macroscopic conservation laws for mass, momentum and solute are obtained by spatial averaging of the respective microscopic conservation equations. Assuming local thermal equilibrium, a single equation for the conservation of the mixture energy is then written. A single equation can be obtained for the solute as well by invoking a proper microsegregation rule. The numerical implementation in a two‐dimensional finite element code is then detailed. Lastly, some examples of simulations of academic tests as well as industrial applications for continuous casting of steel slabs are discussed. They particularly enlighten the ability of the formulation to describe the formation of central macrosegregation during the secondary cooling of slab continuous casting processes. Copyright © 2006 John Wiley & Sons, Ltd.     

An integrated,finite element‐based process model for the analysis of flow,heat transfer,and solidification in a continuous slab caster

An integrated, finite element‐based process model is presented for the prediction of full three‐dimensional flow, heat transfer, and solidification occurring in a continuous caster. Described in detail are the basic models for the analysis of turbulent flow and heat transfer in the liquid steel zone, in the zone of mixture of the liquid steel and solidified steel, and in the solidified zone. Then, the models are integrated to form a process model which can take into account the strong interdependence between the heat transfer behaviour and the flow behaviour. The capability of the process model to reveal the detailed aspects of turbulent flow, heat transfer, and solidification occurring in a continuous caster is demonstrated through a series of process simulations. Copyright © 2003 John Wiley & Sons, Ltd.     

Control volume capacitance method for solidification modelling

The apparent and effective heat capacitance methods are popular finite element formulations used for solidification problems where conduction predominates over other heat transfer mechanisms. These methods involve the specification of element or nodal capacitances to accommodate for the release of latent heat. Unfortunately, they suffer from a major drawback in that energy is not correctly transported through elements so providing a source of inaccuracy. In this paper a capacitance method that considers the elements as control volumes is introduced. Elemental capacitances are prescribed so as to ensure that the Unsteady Flow Energy Equation (USFEE) for each element is satisfied. The new method allows for the transport of mass arising from volumetric shrinkage and ensures that energy is correctly transported. A comparison is made between the method and the well‐known temporal and spatial approximations of apparent heat capacitance, and effective capacitance. It is shown that these approaches can be highly inaccurate when energy transport is used as a criteria for judging them. Copyright © 1999 John Wiley & Sons, Ltd.     

Modelling the pressure die casting process using a hybrid Finite‐Boundary Element model

In this paper an efficient three‐dimensional hybrid thermal model for the pressure die casting process is described. The Finite Element Method (FEM) is used for modelling heat transfer in the casting, and the Boundary Element Method (BEM) for the die. The FEM can efficiently account for the non‐linearity introduced by the release of latent heat on solidification, whereas the BEM is ideally suited for modelling linear heat conduction in the die, as surface temperatures are of principal importance. The FE formulation for the casting is based on the modified effective capacitance method, which provides high accuracy and unconditional stability. This is essential for accurate modelling of the pressure die casting process and efficient coupling to the BEM. The BE model caters for surface phenomena such as boiling in the cooling channels, which is important, as this effectively controls the manner in which energy is extracted. The die temperature is decomposed into two components, one a steady‐state part and the other a time‐dependent perturbation. This approach enables the transient die temperatures to be calculated in an efficient way, since only die surfaces close to the die cavity are considered in the perturbation analysis. A multiplicative Schwarz method for non‐overlapping domains is used to couple the individual die blocks and casting. The method adopted makes use of the weak coupling between the domains, which is a result of the relatively high interfacial thermal resistance that is present. Numerical experiments are performed to demonstrate the computational effectiveness of the approach. Predicted die and casting temperatures are compared with thermocouple measurements and good agreement is indicated. Copyright © 1999 John Wiley & Sons, Ltd.     

Consistent coupling of beam and shell models for thermo‐elastic analysis

In this paper, the finite element formulation of a transition element for consistent coupling between shell and beam finite element models of thin‐walled beam‐like structures in thermo‐elastic problems is presented. Thin‐walled beam‐like structures modelled only with beam elements cannot be used to study local stress concentrations or to provide local mechanical or thermal boundary conditions. For this purpose, the structure has to be modelled using shell elements. However, computations using shell elements are a lot more expensive as compared to beam elements. The finite element model can be more efficient when the shell elements are used only in regions where the local effects are to be studied or local boundary conditions have to be provided. The remaining part of the structure can be modelled with beam elements. To couple these two models (i.e. shell and beam models) at transitional cross‐sections, transition elements are derived here for thermo‐elastic problems. The formulation encloses large displacement and rotational behaviour, which is important in case of thin‐walled beam‐like structures. Copyright © 2004 John Wiley & Sons, Ltd.     

A stabilized volume‐averaging finite element method for flow in porous media and binary alloy solidification processes

A stabilized equal‐order velocity–pressure finite element algorithm is presented for the analysis of flow in porous media and in the solidification of binary alloys. The adopted governing macroscopic conservation equations of momentum, energy and species transport are derived from their microscopic counterparts using the volume‐averaging method. The analysis is performed in a single domain with a fixed numerical grid. The fluid flow scheme developed includes SUPG (streamline‐upwind/Petrov–Galerkin), PSPG (pressure stabilizing/Petrov–Galerkin) and DSPG (Darcy stabilizing/Petrov–Galerkin) stabilization terms in a variable porosity medium. For the energy and species equations a classical SUPG‐based finite element method is employed. The developed algorithms were tested extensively with bilinear elements and were shown to perform stably and with nearly quadratic convergence in high Rayleigh number flows in varying porosity media. Examples are shown in natural and double diffusive convection in porous media and in the directional solidification of a binary‐alloy. Copyright © 2004 John Wiley & Sons, Ltd.     

An evaluation of limited‐memory sparse linear solvers for thermo‐mechanical applications

We consider the performance of sparse linear solvers for problems that arise from thermo‐mechanical applications. Such problems have been solved using sparse direct schemes that enable robust solution at the expense of memory requirements that grow non‐linearly with the dimension of the coefficient matrix. In this paper, we consider a class of preconditioned iterative solvers as a limited‐memory alternative to direct solution schemes. However, such preconditioned iterative solvers typically exhibit complex trade‐offs between reliability and performance. We therefore characterize such trade‐offs for systems from thermo‐mechanical problems by considering several preconditioning schemes including multilevel methods and those based on sparse approximate inversion and incomplete matrix factorization. We provide an analysis of computational costs and memory requirements for model thermo‐mechanical problems, indicating that certain incomplete factorization schemes can achieve good performance. We also provide empirical evaluations that corroborate our analysis and indicate the relative effectiveness of different solution schemes. Our results indicate that our drop‐threshold incomplete Cholesky preconditioning is more robust, efficient and flexible than other popular preconditioning schemes. In addition, we propose preconditioner reuse to amortize preconditioner construction cost over a sequence of linear systems that arise from non‐linear solutions in a plastic regime. Copyright © 2007 John Wiley & Sons, Ltd.     

Efficient 3D‐finite element formulation for thin mechanical and piezoelectric structures

It is the aim to compute efficiently the deformations of the mechanical structures that are excited or damped by piezoelectric actuators. They are treated as 3D structures to have much flexibility. Special design of the finite element concept is required since the structures are thin walled and locking effects have to be avoided. Although the computations are performed in the framework of 3D elasticity, we use ideas from modern plate elements and mixed methods. Copyright © 2007 John Wiley & Sons, Ltd.     

A thermo‐hydro‐mechanical model for multiphase geomaterials in dynamics with application to strain localization simulation

In this paper, the non‐isothermal elasto‐plastic behaviour of multiphase geomaterials in dynamics is investigated with a thermo‐hydro‐mechanical model of porous media. The supporting mathematical model is based on averaging procedures within the hybrid mixture theory. A computationally efficient reduced formulation of the macroscopic balance equations that neglects the relative acceleration of the fluids, and the convective terms is adopted. The modified effective stress state is limited by the Drucker–Prager yield surface. Small strains and dynamic loading conditions are assumed. The standard Galerkin procedure of the finite element method is applied to discretize the governing equations in space, while the generalized Newmark scheme is used for the time discretization. The final non‐linear set of equations is solved by the Newton method with a monolithic approach. Coupled dynamic analyses of strain localization in globally undrained samples of dense and medium dense sands are presented as examples. Vapour pressure below the saturation water pressure (cavitation) develops at localization in case of dense sands, as experimentally observed. A numerical study of the regularization properties of the finite element model is shown and discussed. A non‐isothermal case of incipient strain localization induced by temperature increase where evaporation takes place is also analysed. Copyright © 2016 John Wiley & Sons, Ltd.     

凝固速度对奥氏体不锈钢定向凝固组织及其固液界面稳定性的影响

本文研究了凝固速率对1Cr18Ni9Ti不锈钢定向凝固组织及其固液界面稳定性转变规律的影响.结果表明,在某特一定的温度梯度下,随着凝固速度的增加,定向凝固的固液界面由平面转变为胞状晶,再转变为树枝晶.研究发现,随着凝固速率的增大,定向凝固组织枝晶形貌逐渐细化,枝晶间距减小.     

Optimization of thermo‐elasto‐plastic processes using Eulerian sensitivity analysis

A computational scheme for the analysis and optimization of quasi‐static thermo‐mechanical processes is presented in this paper. In order to obtain desirable mechanical transformations in a workpiece using a thermal treatment process, the optimal control parameters need to be determined. The problem is addressed by posing the process as a decoupled thermo‐mechanical finite element problem and performing an optimization using gradient methods. The forward problem is solved using the Eulerian formulation since it is computationally more efficient compared to an equivalent Lagrangian formulation. The design sensitivities required for the optimization are developed analytically using direct differentiation. This systematic design approach is applied to optimize a laser forming process. The objective is to maximize the angular distortion of a specimen subject to the constraint that the phase transition temperature is not exceeded at any point in the model. Copyright © 2003 John Wiley & Sons, Ltd.     

Adaptive time stepping strategy for solidification processes based on modified local time truncation error

Adaptive time step methods provide a computationally efficient means of simulating transient problems with a high degree of numerical accuracy. However, choosing appropriate time steps to model the transient characteristics of solidification processes is difficult. The Gresho–Lee–Sani predictor–corrector strategy, one of the most commonly applied adaptive time step methods, fails to accurately model the latent heat release associated with phase change due to its exaggerated time steps while the apparent heat capacity method is applied. Accordingly, the current study develops a modified local time truncation error‐based strategy designed to adaptively adjust the size of the time step during the simulated solidification procedure in such a way that the effects of latent heat release are more accurately modeled and the precision of the computational solutions correspondingly improved. The computational accuracy and efficiency of the proposed method are demonstrated via the simulation of several one‐dimensional and two‐dimensional thermal problems characterized by different phase change phenomena and boundary conditions. The feasibility of the proposed method for the modeling of solidification processes is further verified via its applications to the enthalpy method. Copyright © 2009 John Wiley & Sons, Ltd.     

A stabilized finite element formulation for monolithic thermo‐hydro‐mechanical simulations at finite strain

An adaptively stabilized monolithic finite element model is proposed to simulate the fully coupled thermo‐hydro‐mechanical behavior of porous media undergoing large deformation. We first formulate a finite‐deformation thermo‐hydro‐mechanics field theory for non‐isothermal porous media. Projection‐based stabilization procedure is derived to eliminate spurious pore pressure and temperature modes due to the lack of the two‐fold inf‐sup condition of the equal‐order finite element. To avoid volumetric locking due to the incompressibility of solid skeleton, we introduce a modified assumed deformation gradient in the formulation for non‐isothermal porous solids. Finally, numerical examples are given to demonstrate the versatility and efficiency of this thermo‐hydro‐mechanical model. Copyright © 2015 John Wiley & Sons, Ltd.     

Modelling of reinforced polymer composites subject to thermo‐mechanical loading

A coupled finite element model is developed to analyse the thermo‐mechanical behaviour of a widely used polymer composite panel subject to high temperatures at service conditions. Thermo‐chemical and thermo‐mechanical models of previous researchers have been extended to study the thermo‐chemical decomposition, internal heat and mass transfer, deformation and the stress state of the material. The phenomena of heat and mass transfer and thermo‐mechanical deformation are simulated using three sets of governing equations, i.e. energy, gas mass diffusion and deformation equations. These equations are then assembled into a coupled matrix equation using the Bubnov–Galerkin finite element formulation and then solved simultaneously at each time interval. An experimentally tested 1.09 cm thick glass‐fibre woven‐roving/polyester resin composite panel is analysed using the numerical model. Results are presented in the form of temperature, pore pressure, deformation, strain and stress profiles and discussed. The maximum normal stress failure criterion is used in order to establish the load‐bearing capability of the composite panel. Significant pore gas pressure build‐ups (to 0.8 MPa and higher) have been perceived at high thermo‐chemical decomposition rates where the material experiences a complex expansion/contraction phenomenon. It is found that the composite panel experiences structural instability at elevated temperatures up to 300°C but retains its integrity even under moderate external loading. Copyright © 2005 John Wiley & Sons, Ltd.     

An adjoint method for the inverse design of solidification processes with natural convection

This paper presents a finite element algorithm based on the adjoint method for the design of a certain class of solidification processes. In particular, the paper addresses the design of directional solidification processes for pure materials such that a desired freezing front heat flux and growth velocity are achieved. This is the first time that an infinite-dimensional continuum adjoint formulation is obtained and implemented for the solution of such inverse/design problems with moving boundaries and Boussinesq incompressible flow. The present design problem belongs to a category of inverse problems in which one is looking for the unknown conditions in part of the boundary, while overspecified boundary conditions are supplied in another part of the boundary (here the freezing interface). The solidification design problem is mathematically posed as a whole time-domain optimization problem. The gradient of the cost functional is calculated using the solution of an appropriately defined continuous adjoint problem. The minimization process is realized by the conjugate gradient method via the solutions of the direct, adjoint and sensitivity sub-problems. The proposed methodology is demonstrated with the solidification of an initially superheated liquid aluminum confined in a square mold. The non-uniformity in the casting product in the direction of gravity due to the existence of natural convection in the melt is emphasized. The inverse design problem is then posed as finding the appropriate spatial-temporal variations of the boundary heat flux on the vertical mold walls that can eliminate or reduce the effects of convection on the freezing interface heat fluxes and growth velocity. The numerical example demonstrates the accuracy and convergence of the adjoint formulation. Finally, open related research design problems are discussed. © 1998 John Wiley & Sons, Ltd.     

A non‐physical enthalpy method for the numerical solution of isothermal solidification

In this paper, a new formulation for the solution of the discontinuous isothermal solidification problem is presented. The formulation has similarities with the now classical capacitance and source methods traditionally used in commercial software. However, the new approach focuses on the solution of the governing enthalpy‐transport equation rather than the governing parabolic partial differential heat equation. The advantage is that discontinuous physics can be accounted for without approximation and the arbitrariness common to classic approaches is avoided. Also introduced is the concept of non‐physical enthalpy, which unlike physical enthalpy has numerical values that are not moving‐frame invariant. Understanding the behaviour of the non‐physical enthalpy is central to the successful treatment of discontinuities. A particular drawback is that non‐physical enthalpy is non‐intuitive and new mathematical constructs are required to describe its behaviour. This involves the introduction of transport equations, which provide the new concept of relative moving‐frame invariance for the non‐physical enthalpy. The principal advantage, however, is that a unified methodology is established for the treatment of discontinuities. This is shown to establish real rigour and in many respects the formulation highlights the erroneous choices made with established classical approaches and casts in a totally new light a somewhat traditional problem. The new methodology is applied to a range of simple problems not only to provide an in‐depth treatment and for ease of understanding but also to best describe the behaviour of the non‐intuitive non‐physical enthalpy. Demonstrated in the paper is the methods' remarkable accuracy and stability. Copyright © 2010 John Wiley & Sons, Ltd.     

Ti-6Al-4V熔模精密铸造充型及凝固过程计算机模拟

应用自行开发的基于微机上运行的铸件凝固 /充型计算机模拟软件 ,对Ti-6Al-4V钛合金薄壁件精密铸造的充型及凝固传热过程进行了模拟分析 .应用自行安装的多通道钨铼热电耦温度数据计算机采集、分析系统 ,测定了该钛合金起吊接头精密铸件的凝固冷却曲线 ,获取了该合金有关的凝固参数 .对包括上述零件在内的钛合金薄壁件精密铸造的充型过程及凝固传热的温度分布进行了数值模拟 ,模拟计算与实测结果合理吻合 .基于该研究可对其精密铸造工艺进行优化设计 .     

Efficient numerical implementation of pressure,time, and temperature superposition for elasto‐visco‐plastic material model by using a symbolic approach

This article is concerned with the finite element implementation of an elasto‐visco‐plastic constitutive model using a symbolic approach. The model combines the Knauss–Emri (KE) pressure, temperature, and time superposition principle in the implicit finite element scheme. The equation development and code generation was performed using the symbolic tool AceGen. The same symbolic system was applied to derive analytical sensitivities of the numerical model with respect to the material and shape parameters. To enable efficient numerical implementation of the KE model the convolution integrals were transformed into their respective incremental forms, so that radical improvements of code efficiency and computer storage requirements were achieved. The numerical examples derived for polyethylene terephthalate (PET) polymers demonstrate that symbolic systems can be applied to develop complex constitutive models capable of simulating material responses that are in good agreement with experimental measurements over a wide range of strain rates, temperatures, and loading conditions. Copyright © 2010 John Wiley & Sons, Ltd.     

On the optimal cooling strategy for variable‐speed continuous casting

In this paper, we consider the inverse problem of determining the optimal cooling parameters for continuous casting under changing casting speed. We rely on automatic differentiation to support different search methods for the parameter values that will minimize a given cost functional, which can include a variety of criteria: surface temperature evolution and variation, interface position, full solidification point. In the direct problem we use a fixed‐domain transformation to solve the corresponding free‐boundary problem to high accuracy. Numerical experiments are provided to illustrate and support the effectiveness of the present concept. Copyright © 2001 John Wiley & Sons, Ltd.