A three-dimensional steady state thermal fluid model of jumbo ingot casting during electron beam re-melting of Ti–6Al–4V

A 3-D coupled thermal-fluid model describing mass, momentum and energy transport within a Ti–6Al–4V rolling ingot cast in an (Electron Beam Cold Hearth Remelting) EBCHR process has been developed to describe steady state casting conditions. The model incorporates a number of the physical phenomena inherent to the industrial process, including a metal inlet in the center of one of the narrow faces, complex boundary conditions based on industrial practice, buoyancy driven flow within the liquid and flow attenuation using a Darcy momentum source term within the mushy zone. The model ignores turbulence in the liquid pool and Marangoni (surface tension) driven surface flows. The model has been validated against liquid pool depth and profile measurements made on an experimental casting seeded with insoluble dense markers and doped with dense alloy additions. Comparisons have also been made to video images taken of the top surface during casting. The results indicate that the model is able to quantitatively predict the steady state sump depth and profile and is able to qualitatively predict aspects of the top surface temperature distribution. The model has also been used to conduct a process heat balance and sensitivity analyses. The process heat balance conducted on the model domain indicates that at steady state the liquid metal inlet contributes 88% of the total power input, while the electron beam provides net 12% after accounting for radiation losses from the top surface; 62% of the heat is lost through the ingots sides and the balance is lost via bulk transport of sensible heat through the bottom of the domain. The results of the sensitivity analysis on pool depth indicate that casting rate has the largest effect followed by metal inlet superheat. The thermal, flow and pressure fields predicted by the steady state model serves as the initial conditions for a transient hot-top model, which is the subject of a forth-coming paper.     

Flow and heat transfer for a power-law electrically conducting fluid flowing between parallel plates under transverse magnetic field with viscous dissipation

The flow and heat transfer problem with viscous dissipation for electrically conducting non-Newtonian fluids with power-law model in the thermal entrance region of two parallel plates with magnetic field under constant heat flux and constant wall temperature conditions has been studied. The governing equations have been solved numerically using quasilinearization technique and implicit finite-difference scheme. It has been found that the effect of viscous dissipation on heat transfer is quite significant for heating and cooling conditions at the wall.     

Numerical simulation of powder mixed electric discharge machining (PMEDM) using finite element method

In the present paper, an axisymmetric two-dimensional model for powder mixed electric discharge machining (PMEDM) has been developed using the finite element method (FEM). The model utilizes the several important aspects such as temperature-sensitive material properties, shape and size of heat source (Gaussian heat distribution), percentage distribution of heat among tool, workpiece and dielectric fluid, pulse on/off time, material ejection efficiency and phase change (enthalpy) etc. to predict the thermal behaviour and material removal mechanism in PMEDM process. The developed model first calculates the temperature distribution in the workpiece material using ANSYS (version 5.4) software and then material removal rate (MRR) is estimated from the temperature profiles. The effect of various process parameters on temperature distributions along the radius and depth of the workpiece has been reported. Finally, the model has been validated by comparing the theoretical MRR with the experimental one obtained from a newly designed experimental setup developed in the laboratory.     

A mathematical model of the heat transfer process in a shell and tube condenser for use in refrigeration applications

This paper describes a mathematical model that may be used in predicting the heat transfer performance of a shell and tube condenser. The model uses the Effectiveness-Number of Transfer Units (E-NTU) method of heat exchanger analysis. Given the geometric characteristics, the flow conditions and inlet fluid temperatures the model determines, (a), the necessary heat transfer coefficients; (b), the fractions of the condenser devoted to desuperheating, condensing and subcooling the condensing medium; (c), the total heat rejection; and (d), the exit fluid temperatures.The model has been validated by testing a typical condenser at various operating conditions. The measured performance has been compared with that predicted theoretically and a close correlation has been found to exist between the two.     

Buoyancy-assisted flow of yield stress fluids past a cylinder: Effect of shape and channel confinement

The aiding-buoyancy mixed convection heat transfer in Bingham plastic fluids from an isothermal cylinder of elliptical and circular shape in a vertical adiabatic channel is numerically investigated. For a fixed shape of the elliptical cylinder E = 2 (ratio of major to minor axes), the effect of confinement is studied for three values of blockage ratio, B, defined as the ratio of the channel width to the circumference of the cylinder/π, as 6.5, 2.17 and 1.3. In order to delineate the role of cross-section of the cylinder, results are also presented here for a circular cylinder of the same heat transfer area as the elliptical cylinder. The results presented herein span the range of conditions as: Bingham number, 0 ≤ Bn ≤ 100, Reynolds number, 1 ≤ Re ≤ 40, and Prandtl number, 1 ≤ Pr ≤ 100 over the range of Richardson number Ri = 0 (pure forced convection) to Ri = 10. Extensive results on drag coefficient, local and surface averaged values of the Nusselt number and yield surfaces are presented herein to elucidate the combined effects of buoyancy, blockage ratio and fluid yield stress. The morphology of the yield surfaces shows that the unyielded plug regions formed upstream and downstream of the cylinder grow faster at low Reynolds numbers with the increasing yield stress effects under the weak buoyancy forces, i.e., small values of Grashof or Richardson number. The heat transfer enhancement is observed with the increasing channel-confinement due to the sharpening of the temperature gradients near the surface of the cylinder. The average Nusselt number shows a positive dependence on the Reynolds number, Prandtl number and Richardson number irrespective of the shape of the cylinder or the type of fluid. By employing the modified definitions of the dimensionless parameters (based on the two choices of the overall effective fluid velocity), predictive correlations have been established for estimating the value of the average Nusselt number in a new application.     

Unsteady state heat flow in epidermis and dermis of a human body

We investigate the unsteady state temperature distribution in human skin where subcutaneous tissues are not present. The mathematical model is employed for a onedimensional unsteady state case, taking the blood mass flow rate and metabolic heat generation variable with respect to the position in the dermis. The metabolic heat generation depends on the tissue temperature. The thermal conductivity is taken constant but different in two layers. The problem has been solved using Laplace transform and Bessel functions. Numerical results for a simple case are discussed.     

The postbuckling analysis of laminated circular plate with elliptic delamination

Based on the Von Karman plate theory, considering the effect of transverse shear deformation, and using the method of the dissociated three regions, the postbuckling governing equations for the axisymmetric laminated circular plates with elliptical delamination are derived. By using the orthogonal point collocation method, the governing equations, boundary conditions and continuity conditions are transformed into a group of nonlinear algebraically equation and the equations are solved with the alternative method. In the numerical examples, the effects of various elliptical in shape, delamination depth and different material properties on buckling and postbuckling of the laminated circular plates are discussed and the numerical results are compared with available data.     

A model of the electrothermal ribbon printing process

A sequence of mathematical models describing the electrothermal ribbon printing process is developed. The models describe the electrical processes, heat generation and heat transfer within the ribbon and the transfer of ink from the ribbon to paper. Account has been taken of the nonlinear electrical properties of the ribbon. A model of the paper surface has been developed in order to model the transfer of the ink from the ribbon to the paper. The partial differential equations describing the electric field, the heat flow and the stresses in the ink have been solved using standard techniques.     

Laplace方程有孔椭圆区域边值问题的解析解

本文利用相似流动替换方法 ,解决了中心有圆孔的椭园形区域上 Laplace方程第一类边值问题 ;采用分区域解法 ,给出了中心有椭园孔的椭园形区域上 Laplace方程第一类边值问题的解析通解 .这一结果在许多工程领域有重要应用 ,本文给出了油藏工程实例     

Microcomputer-based simulation of heat conduction between solid of tapered shape and the fluid

Simulating the heat conduction in between a solid conducting body immersed in fluid at a given temperature is a difficult task, particularly when the body is tapered in shape and the costs have to be kept low. The body in question is cylindrical, symmetrical about z-axis, tapered in shape and has been heated to a high temperature before being immersed into the fluid. The heat conduction equation in cylindrical polar coordinates with all derivative boundary conditions is attempted to be solved in two ways – first analytically making use of Bessel's function and then by numerical modelling with the help of Finite Difference method, and equations thus formed have been solved through ADI explicit and Implicit (Peaceman Rachford) scheme on microcomputer. The paper is an account of work already done on this and includes further possibilities for general solution with analytical methods and a suitable low-cost numerical solution. Also possible analogy with flow of fluids have been explored. (© 2008 WILEY-VCH Verlag GmbH & Co. KGaA, Weinheim)     

Modelo de un proceso de cristalización continua de un sorbete por medio de la metodología de momentos

Freezing is an important step in the manufacturing process of ice-cream and sorbet, since the operating conditions have a strong influence on the micro-structure, and consequently on the sensorial attributes of the final product. This steep of freezing is carried out by a scraped surface heat exchanger (SSHE) where the product quality is conditioned by process conditions as the evaporation temperature of a refrigerant fluid, the mix flow rate, the dasher speed and the cylinder pressure due to the air introduction. In order to study the relevance of a control system based on the influence of process variables on product quality, this paper presents a model for a continuous crystallization of a sorbet using the method of moments, which is validated by experimental data.The model created by this methodology has been able to represent the influence of the process conditions during the crystallization of the sorbet on the final product characteristics such as crystal size and the draw temperature in the outlet of the SSHE in absence of air. The model based in moments is studied as a reduced model of the population balance equation and includes the phenomena of heterogeneous nucleation and growth. This model developed represents minimal computational requirements and is highly adapted for optimization and/or process control tasks.     

Magnetohydrodynamic non-Darcy mixed convection heat transfer from a vertical heated plate embedded in a porous medium with variable porosity

A numerical model is developed to study magnetohydrodynamics (MHD) mixed convection from a heated vertical plate embedded in a Newtonian fluid saturated sparsely packed porous medium by considering the variation of permeability, porosity and thermal conductivity. The boundary layer flow in the porous medium is governed by Forchheimer–Brinkman extended Darcy model. The conservation equations that govern the problem are reduced to a system of non-linear ordinary differential equations by using similarity transformations. Because of non-linearity, the governing equations are solved numerically. The effects of magnetic field on velocity and temperature distributions are studied in detail by considering uniform permeability (UP) and variable permeability (VP) of the porous medium and the results are discussed graphically. Besides, skin friction and Nusselt number are also computed for various physical parameters governing the problem under consideration. It is found that the inertial parameter has a significant influence in increasing the flow field and the rate of heat transfer for variable permeability case. The important finding of the present work is that the magnetic field has considerable effects on the boundary layer velocity and on the rate of heat transfer for variable permeability of the porous medium. Further, the results obtained under the limiting conditions were found to be in good agreement with the existing ones.     

任意形状孔口单边裂纹问题的边界配位解法

本文提出了一组复应力函数,采用边界配位方法对不同形状孔口(包括圆、椭圆、矩形及菱形孔口)的单边裂纹平板的应力强度因子进行了计算.计算结果表明,对长度和宽度远大于孔口和裂纹几何尺寸的试件,配位法与用其他方法所得的无限大板含圆或椭圆孔边裂纹问题的解符合得很好.同时,对其他孔口问题,特别是有限大板情形,本文给出了一系列计算结果.本文所提出的函数及计算过程可以应用于任意形状孔口单边裂纹平板的计算.     

Unsteady MHD stagnation-point flow with heat and mass transfer in a micropolar fluid in the presence of thermophoresis and suction/injection

The effect of suction or injection on unsteady MHD flow with heat and mass transfer in a micropolar fluid near the forward stagnation point flow with thermophoresis has been investigated. The problem is reduced to a system of non-dimensional partial differential equations, which are solved numerically using the implicit finite-difference scheme. Profiles for velocity, microrotation, temperature and concentration as well as the skin friction, the rate of heat and mass transfer are determined and presented graphically for physical parameters. The results show that the suction increases the skin friction, the rate of heat and mass transfer while opposite trend is observed for the case of injection. It is also found that the effect of thermophoresis is decrease the concentration boundary layer thickness.     

A numerical study of boundary layer flow of viscous incompressible fluid past an inclined stretching sheet and heat transfer using nonpolynomial spline method

In the present paper, we study the boundary layer flow of viscous incompressible fluid over an inclined stretching sheet with body force and heat transfer. Considering the stream function, we convert the boundary layer equation into nonlinear third-order ordinary differential equation together with appropriate boundary conditions in an infinite domain. The nonlinear boundary value problem has been linearized by using the quasilinearization technique. Then, we develop a nonpolynomial spline method, which is used to solve the flow problem. The convergence analysis of the method is also discussed. We study the velocity function for different angles of inclination and Froude number with the help of various graphs and tables. Then using these in heat convection flow, we obtain the expression for temperature field. Skin friction is also calculated. The various results have been given in tables. At last, we calculated the Nusselt number.     

Convective flow and heat transfer of a viscous heat generating fluid in the presence of a moving,infinite, vertical,porous plate

The analysis of convective flow and heat transfer of a viscous heat generating fluid past a uniformly moving, infinite, vertical, porous plate has been made systematically with a view to throw adequate light on the effects of the plate-motion and the presence of heat generation/absorption on the flow and heat transfer characteristics. The equations of conservation of momentum and energy which govern the flow and heat transfer of the said problem have been solved numerically by the method of Runge-Kutta-Gill. The numerical results thus obtained for the flow and heat transfer characteristics have revealed many an interesting behaviour, of the skin friction and the rate of heat transfer coefficient at the plate.     

Mathematical modelling of spark-ignition engines

The flow field, scavenging efficiency, power output, heat transfer losses, and unburned hydrocarbon emissions have been numerically studied by means of a two-equation model of turbulence in a four-stroke, homogeneous-charge, spark-ignition engine. The engine is equipped with an intake valve, an exhaust valve, and a constant rate heat source which simulates the spark plug. Combustion has been modelled by means of a one-step irreversible chemical reaction whose rate is controlled by an Arrhenius-type expression. The numerical results indicate that the intake stroke is characterized by the formation of two eddies which persist in the compression stroke. Turbulence is generated at the shear layers of the air jet drawn into the cylinder, but its level decreases in the compression stroke. Due to the heat released by the spark plug and the chemical reaction, a spherical flame kernel is formed. This kernel evolves into a cylindrical flame when the flame front reaches the piston. Fuel remains unburnt at the corner between the cylinder head and the cylinder wall due to heat transfer losses. The numerical results also indicate that despite uncertainties about the turbulence and heat transfer models, an engine model such as the one studied here can be used to understand the flow field, heat transfer losses, scavenging efficiency, and power output in conventional spark-ignition engines. Such capabilities are very helpful in the development and optimization stages of engines. For example, here the engine model thermal and scavenging efficiencies are 15.69% and 94%, respectively. The peak pressure is 33 atm and occurs at 6° ATDC. The unburnt hydrocarbon emissions are 7.41% of the total fuel admitted into the cylinder.     

The use of artificial intelligence technique for the optimisation of process parameters used in the continuous casting of steel

The productivity and quality of a continuous caster depend mainly on process parameters, i.e. casting speed, casting temperature, steel composition and cleanliness of the melt, water flow rates in the different cooling zones, etc. This work presents the development of an algorithm, which incorporates heuristic search techniques for direct application in metallurgical industries, particularly those using continuous casting process for the production of steel billets and slabs. This is done to determine the casting objectives of maximum casting rate as a function of casting constraints. These constraints are evaluated with the aid of a heat transfer and solidification model based on the finite difference technique, which has been developed and integrated with a genetic algorithm. The essential parts of continuous casting equipment, which must be subjected to monitoring, as well as a methodology of mathematical model and physical settlements in each cooling region, are presented. The efficiency of the intelligent system is assured by the optimisation of the continuous casting operation by maximum casting rate and defect-free products. This approach is applied to the real dimension of a steel continuous caster, in real conditions of operation, demonstrating that good results can be attained by using heuristic search, such as: smaller temperature gradients between sprays zones, reduction in water consumption and an increase in casting speed.     

Calculation of conjugate heat transfer problem with volumetric heat generation using the Galerkin method

A mathematical model of fluid flow across a rod bundle with volumetric heat generation has been built. The rods are heated with volumetric internal heat generation. To construct the model, a volume average technique (VAT) has been applied to momentum and energy transport equations for a fluid and a solid phase to develop a specific form of porous media flow equations. The model equations have been solved with a semi-analytical Galerkin method. The detailed velocity and temperature fields in the fluid flow and the solid structure have been obtained. Using the solution fields, a whole-section drag coefficient C_d and a whole-section Nusselt number Nu have also been calculated. To validate the developed solution procedure, the results have been compared to the results of a finite volume method. The comparison shows an excellent agreement. The present results demonstrate that the selected Galerkin approach is capable of performing calculations of heat transfer in a cross-flow where thermal conductivity and internal heat generation in a solid structure has to be taken into account. Although the Galerkin method has limited applicability in complex geometries, its highly accurate solutions are an important benchmark on which other numerical results can be tested.     

Unteady heat flow and temperature variation in human SST regions

The temperature distribution in human skin and subdermal tissue layer is presented using bioheat transfer equation. The body temperature is determined by the balance between heat produced and heat lost by our body. The time-dependent solutions have been found to be affected by the metabolic heat genaration rate, blood mass flow, the rate of evaporation of perspiration and also by the atmospheric temperature. The analytic solutions for different layers have been calculated numerically and are also shown graphically.