Calculation of Structural Characteristics Evolution during Superplastic Forming of Shells by "SPLEN-O" Application Computer Program Set

The applications of commercial computer program set "SPLEN-O" based on finite elements method (FEM) for the simulation of superplastic forming (SPF) technology of shells are described. The changes in characteristics of ultrafine-grained (UFG) structure during deformation are taken into account in function of viscosity and solving algorithm. Some examples are shown to illustrate the possibilities of FEM simulation for prediction of numerical grain-size data on different SPF stages of shells.     

Numerical Simulation and Water Analog of Mold Filling Processes

This paper demonstrates the potential of a computer code, developed by the authors, in shaping gating systems by modeling the fluid flow phenomena through a complex gating system during mold filling. A plate casting with dimension 200 mm×200 mm×50 mm was chosen as the verifying problem. Water analog studies were carried out on this casting. The comparison indicates that computer simulation could be a powerful tool in shaping gating systems.     

Study on Numerical Simulation of Mold Filling and Solidification Processes under Pressure Conditions

The mold filling and solidification simulation for the high pressure die casting (HPDC) and low pressure die casting (LPDC) processes were studied.A mathematical model considering the turbulent flow and heat transfer phenomenon during the HPDC process has been established and paralled computation technique was used for the mold filling simulation of the process.The laminar flow characteristics of the LPDC process were studied and a simplified model for the mold filling process of wheel castings has been developed.For the solidification simulation under pressure conditions,the cyclic characteristics and the complicated boundary conditions were considered and techniques to improve the computational efficiency are discussed.A new criterion for predicting shrinkage porosity of Al alloy under low pressure condition has been developed in the solidification simulation process.     

Quick-homogeneous Corrosion of Ti-2A1-2.5Zr Alloy in High-temperature and High-pressure Water Steam

The corrosion behavior of Ti-2A1-2.5Zr alloy with 5 alloy contents and 5 surface states were studied in water steam at 400℃, 10.3 MPa for 72 h. The weight-increments of all samples are under 4 mg/dm2, better than Zr and Zr-alloy. or-Ti is oxidized into anatase-type TiO2 preferentially. The corrosion resistance is improved by adding Al element or pre-oxidizing treatment, the latter is more effective relatively.     

Modelling of Mould Filling and Solidification of Castings

An experimental casting for validation has been designed. The casting is composed of two 50×600×2.5 (width×length×thick) thin-wall pieces. One downsprue is located in the middle. A pouring cup with a stopper is used. This design allows to using two different types of moulds simultaneously. An Al-10%Si alloy has been poured at different temperatures. Two effects have been studied: one is the pouring temperature and the other is the moulding method (namely by machine or manually). The filling length is proportional to the pouring temperature. The influence of different moulding methods on mould filling is more complicated. The filling length in the manual-made mould is 1.5 times as long as the one in the machine-made mould due to the different thermal conductivities. Vents have little influence. A finite volume based computer code which can simulate fluid flow during mould filling coupled with heat transfer as well as solidification has been developed in WTCM Foundry Center.. The code can predict cold shut during mould filling and shrinkage defects during solidification. The simulated results are in good agreement with the experiments.In the second part of the paper, an example is given which illustrates how to use computer simulation to aid designing the casting system. The final computational result is compared with the industrial casting. The process of designing castings by using simulation is completely different from the traditional way. The computer aided casting design offers the possibility to obtain a sound casting from the first time.     

Modelling of Mould Filling and Solidification of Castings

An experimental casting for validation has been designed. The casting is composed of two 50×600×2.5 (width×length×thick) thin-wall pieces. One downsprue is located in the middle. A pouring cup with a stopper is used. This design allows to using two different types of moulds simultaneously. An Al-10%Si alloy has been poured at different temperatures. Two effects have been studied: one is the pouring temperature and the other is the moulding method (namely by machine or manually). The filling length is proportional to the pouring temperature. The influence of different moulding methods on mould filling is more complicated. The filling length in the manual-made mould is 1.5 times as long as the one in the machine-made mould due to the different thermal conductivities. Vents have little influence. A finite volume based computer code which can simulate fluid flow during mould filling coupled with heat transfer as well as solidification has been developed in WTCM Foundry Center.. The code can predict cold shut during mould filling and shrinkage defects during solidification. The simulated results are in good agreement with the experiments.In the second part of the paper, an example is given which illustrates how to use computer simulation to aid designing the casting system. The final computational result is compared with the industrial casting. The process of designing castings by using simulation is completely different from the traditional way. The computer aided casting design offers the possibility to obtain a sound casting from the first time.     

Background Simulation and Correction Algorithm in Spot Weld Image Processing

One of the chief works for inspecting spot weld quality by X-ray to obtain an ideal and uniform digital image. This paper introduces three methods of image background simulation algorithm, and' the effect of background correction was compared. It may be safely said that Kalman filter method is simple and fast for general image; the FFT method has a good adaptability for background simulation.     

Optimum Location of Tube Blank in Electromagnetic Bulging

Using analytical method, this paper gets 'the mutual inductance between coil and workpiece in tube blank electromagnetic bulging. According to this, we obtain the optimum locations of tube blank with different length of coil and workpiece. There is a good agreement between results calculated and the experimental data.     

Capacitance of High-Voltage Coaxial Cable in Plasma Immersion Ion Implantation

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Buster Die Shape Design of a Track Link Forging Using FEMBased Back-Tracing Method

For the preform design of a complex track link forging, fifteen critical sections were selected for two dimensional back-tracing using FEM. The preform shapes of the critical sections are designed and integrated into an ideal 3D busting shape. The buster dies are finally designed according to the ideal busting shape with a little of modification. The 3D simulation of the busting stage is carried out.     

Feature-based Design of Welded Structure for Robotic Arc Welding Off-line Programming

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Symmetry-Preserving Discretization of Heat Transfer in a Complex Turbulent Flow

Convective and diffusive operators are discretized such that their symmetries are preserved. The resulting discretization inherits all symmetry-related properties of the continuous formulation. It is shown that a symmetry-preserving discretization is unconditionally stable and conservative. A fourth-order, symmetry-preserving discretization method is developed and tested for the numerical simulation of turbulent (flow and) heat transfer in a channel with surface-mounted cubes, where the temperature is treated as a passive scalar. The Reynolds number (based on the channel width and the mean bulk velocity) is Re=13,000. The results of the numerical simulation agree well with available experimental data.     

Superplastic Solid-Phase Welding of 40 Cr-T10A Steel

The microstructure of 40Cr and T10A steel sample and its surface to be welded is ultra-fined through salt-bath cyclic quenching and high frequency hardening, then the surface is cleaned. Under non-vacuum and no shielded gas, the welding parameter of isothermal superplastic solidphase welding and the effect of surface microstructure prior to pressure welding on the quality of joint are studied. At the temperature of 730~750℃ and at initial strain rate of (2~4) × 10-4 s-l, the strength of the joint is up to or close to that of 40Cr base metal in 3-5 min pressure welding     

微注塑成型中对流换热系数对熔体充模流动的影响

在熔体流动理论的基础上,通过分析熔体的对流传热机理,并引入对流换热系数模型,对微注塑成型中对流换热系数对熔体充模流动进行了研究。在正方形截面分别为500μm、300μm和200μm的三种长方形微流道中,数值模拟了熔体充模流动,通过与已有实验数据相比较,验证了对流换热系数模型的合理性,并分析了不同的模具温度和熔体温度下,采用常数对流换热系数和对流换热系数模型得到的熔体温度分布及其随微流道特征尺度变化规律。     

Study and Application of Mold Filling Simulation of Shaped Castings

In this paper, an algorithm for simulating fluid flow and heat transfer for mold filling of shaped castings is presented. The main features of the algorithm include: 1) a simple but practical technique based on VOF method to determine free surface, 2) an explicit scheme of enthalpy to solve the energy equation more efficiently, and 3) an effective treatment to modify the flux deviation due to pressure iteration. In order to verify these methods, well controlled experiments have been repeatedly done with both water analog and gray iron pouring experiments to record the flow patterns and temperature variations. The calculated results are in accordance with the experimental ones. For the applications, the simulated initial temperature distribution right after mold filling was used to analyse subsequent solidification and to predict shrinkage defects.Actual castings were poured and tested in a foundry plant. The reuslts show that the defects predication with considering fluid flow effects is more precise than that without considering the effects.     

Modeling of Mold Filling and Solidification in Lost Foam Casting

Based on the characteristics of the lost foam casting (LFC) and the artificial neural network technique, a mathematical model for the simulation of the melt-pattern interface movement during the mold filling of LFC has been proposed and experimentally verified. The simulation results are consistent with the experiments in both the shapes of melt front and filling sequences. According to the calculated interface locations, the fluid flow and the temperature distributions during the mold filling and solidification processes were calculated, and the shrinkage defect of a lost foam ductile iron casting was predicted by considering the mold wall movement in LFC. The simulation method was applied to optimize the casting design of lost foam ductile iron castings. It is shown that the model can be used for the defects prediction and for casting design optimization in the practical LFC production.     

Modeling of Heat Transfer and Solidification Process of Spray Formed Billet

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微注塑成型充模流动中的对流换热实验

微注塑成型中,聚合物熔体与微型腔壁面间的对流换热行为与常规注塑成型不同,对流换热系数也发生了变化。通过采用微模具和温度传感器,对聚丙烯(PP)、ABS和两种聚甲醛(POM)熔体,以不同注射速度填充厚度为0.510 mm和0.420 mm,表面粗糙度为0.062μm、0.393μm和0.695μm的不同微型腔时的模具温度分布进行测量,从而求得对流换热系数。结果表明,微注塑成型中对流换热系数,与聚合物材料热物理性质紧密相关,热物性参数值高的材料,对流换热系数也大;且随注射速度和型腔表面粗糙度的增加以及型腔厚度的减小而增大。     

蜂窝板换热器内部流动传热特性研究

建立了蜂窝板换热器湍流流动的物理数学模型,并应用数值分析方法模拟了蜂窝板换热器的三维流动传热过程;分析了不同雷诺数下通道内流动阻力和换热性能及其随雷诺数的变化规律,并与相同当量直径的平行平板通道的流动换热性能进行了对比。结果表明,蜂窝板换热器在换热系数提高的同时流动阻力也增大了,在雷诺数Re=3000~15000的范围内,其传热努塞尔数比平行平板增大了0.93~2.12倍,阻力系数增大了2.24~2.35倍。最后从场协同理论的角度分析了蜂窝板强化传热的机理。     

钨极氩弧点焊熔池中流体流动及传热过程的数值模拟

本文建立了一个描述钨极氩弧点焊熔池中流体动力学状态及传热过程的数值分析模型。该模型考虑到了熔池传热过程的瞬时特点、熔池界面的移动以及电磁力、自然对流和表面张力梯度的综合影响;揭示了熔池内部电磁力场、流场和温度场相互作用的规律;采用了流函数—涡度法以及全隐式差分格式。根据该模型得出的数值分析结果与实验值吻合程度良好。