Thermal analysis of the roll in the strip casting process

Coiled strip can be directly produced through the twin-roll strip casting process from the melt by incorporating casting and hot rolling together into a single step. In this unique process, the strip formation from the molten metal critically relies upon the casting rolls. Thus, the design of the rolls is extremely essential. The coupled heat transfer and deformation analysis of the casting roll is carried out in a two-dimensional numerical model, using a finite element program (MARC) to examine the thermal stress and displacement. The effects of several factors such as the nickel overlay thickness on the roll surface, the casting speed, and the roll diameter on thermal characteristics are investigated.     

Fissuration polymodale dans les matériaux viscoélastiques orthotropes

This Note deals with an algorithmic approach about the crack initiation and the crack growth in a viscoelastic media for mixed mode configurations. This numerical model couples a finite element resolution of viscoelastic behavior and the Mθ integral calculus allowing a mixed mode separation in terms of stress intensity factors and energy release rate. The numerical application uses a 2MCG specimen allowing, in the same time, different mixed mode ratios and a crack growth stability. The finite element algorithm allows us to model the crack tip advance by taking into account the crack lip uncohesion in the process zone. It size is defined by taking into account stress field in the crack tip vicinity. To cite this article: R. Moutou Pitti, F. Dubois, C. R. Mecanique 337 (2009).     

Identification of damage fields using kinematic measurementsIdentification de champs d'endommagement à l'aide de mesures cinématiques

It is proposed to determine damage fields on the surface of a material by using only full-field displacement measurements. A finite element approach is developed for which the unknown damage field is assumed to be piece-wise constant. Two examples are discussed in which the displacement field is either obtained by finite element analyses or measured by digital image correlation. To cite this article: D. Claire et al., C. R. Mecanique 330 (2002) 729–734.     

Remaillage adaptatif pour la mise en forme des tôles minces

Problems associated with finite element simulation of the forming processes are characterized by large elastoplastic deformations, evolutive contact with friction, geometrical nonlinearities inducing a severe distortion of the computational mesh of the domain. In this case, frequent remeshing of the deformed domain during computation are necessary to obtain an accurate solution and complete the computation until the termination of the numerical simulation process. This Note presents a new adaptive remeshing method of thin sheets for numerical simulation of metal forming processes. The proposed method is based on geometrical criteria and does not use the geometry of the forming tools. It is integrated in a computational environment using the ABAQUS solver. Numerical examples are given to show the efficiency of our approach. To cite this article: L. Moreau et al., C. R. Mecanique 333 (2005).     

Numerical simulation of heat transfer in pressurized solidification of Magnesium alloy AM50

Based on finite difference and control-volume scheme, a model was developed to simulate fluid flow in forced convection and heat transfer in pressurized solidification of a cylindrical squeeze casting of magnesium alloy AM50. Pressure-dependent heat transfer coefficients (HTC) and non-equilibrium solidification temperatures were determined by experimental measurements. With the measured HTC and temperatures under the different pressures, the temperature distributions and the cooling behaviors of squeeze cast were simulated.     

Numerical investigation of flow and heat transfer in a gas-droplet separated turbulent stream using the Reynolds stress transfer model

The results of the numerical modeling of flow structure, turbulence, and heat transfer in a gas-droplet stream after sudden tube expansion on the basis of the Eulerian approach are presented. The gas phase turbulence was modeled using the Reynolds stress transfer model modified to allow for the presence of particles. The results are compared with those obtained using the two-equation k-ε model. The latter results overestimate the heat transfer in the separation flow as compared with the Reynolds stress transfer model. The heat transfer is shown to considerably increase, when evaporating droplets are incorporated in the separation flow (by a factor of more than 1.5 compared with the case of a single-phase flow at a small mass concentration of the droplets M _L1 ≤ 0.05). The addition of the disperse phase in the turbulent gas flow leads a slight increase in the recirculation zone length. Good agreement with the experimental data indicates the adequacy of the numerical model developed.     

Nanofluids thermal behavior analysis using a new dispersion model along with single-phase

A numerical study has been performed to analyze nanofluids convective heat transfer. Laminar α-Al₂O₃-water nanofluid flows in an entrance region of a horizontal circular tube with constant surface temperature. Numerical analysis has been carried out using two different single-phase models (homogenous and dispersion) and two-phase models (Eulerian–Lagrangian and mixture). A new model is developed to consider the nanoparticles dispersion. The transport equations for the tube with constant surface temperature were solved numerically using a control volume approach. The effects of nanoparticles volume fraction (0.5, 1 %) and Reynolds number (650 ≤ Re ≤ 2300) on nanofluid convective heat transfer coefficient were studied. The results are compared with the experimental data and it is shown that the homogenous single-phase model is underestimated and the mixture model is overestimated. Although the Eulerian–Lagrangian model gives a reasonable prediction for the thermal behavior of nanofluids, the dispersion single-phase model gives more accurate prediction despite its simplicity.     

Comparison of the Eulerian and Lagrangian approaches in studying the flow pattern and heat transfer in a separated axisymmetric turbulent gas-droplet flow

The Eulerian and Lagrangian approaches are used to perform a numerical study of the disperse phase dynamics, turbulence, and heat transfer in a turbulent gas-droplet flow in a tube with sudden expansion with the following ranges of two-phase flow parameters: initial droplet size d ₁ = 0–200 µm and mass fraction of droplets M _L1 = 0–0.1. The main difference between the Eulerian and Lagrangian approaches is the difference in the predictions of the droplet mass fraction: the Eulerian approach predicts a smaller value of M _L both in the recirculation region and in the flow core (the difference reaches 15–20%). It is demonstrated that the disperse phase mass fraction calculated by the Lagrangian approach agrees better with measured data than the corresponding value predicted by the Eulerian approach.     

Turbine vane film cooling: Heat transfer evaluation using high-order discontinuous Galerkin RANS computations

A high-order accurate CFD solver, based on the Discontinuous Galerkin (DG) finite element method, is here employed to compute the heat transfer, with and without film coolant injection, around a turbine vane extensively tested in a wind tunnel. The numerical solution makes also use of a high-order polynomial representation of the airfoil curved boundary in order to minimize the numerical sources of error, leaving possibly only those related to the physical model adopted. The objective of the work is therefore twofold: on the one hand to provide a detailed investigation, often beyond the reach of the experiments, of the complex flow field arising in a film-cooled gas turbine cascade, on the other hand to ascertain the limits of the Reynolds-averaged Navier-Stokes (RANS) approach and its associated turbulence model when using high-order accurate methods. The DG formulation is briefly reviewed, as well as the experimental apparatus and the measuring technique, and then the code is applied to the computation of various test cases characterized by different reference Reynolds and Mach numbers. Two-dimensional results (up to seventh-order accurate) obtained both with the high- and low-Reynolds version of the k-ω model employed are presented. Reasonably good agreement between experimental and numerical results is obtained, even though the outcomes are far from being completely satisfactory especially for flow regimes in the low Reynolds number range. This is due to the lack of suitable modeling of the laminar-turbulent transition process taking place around the blade leading edge. Such a complex phenomenon is out of reach of the modeling capabilities of the high-Re k-ω model, while can be roughly mimicked by the low-Re version of the model, which is able to provide a delayed onset of the turbulence quantities along the blade surface.Third-order accurate computation of the three-dimensional turbine vane are also presented in this work and compared with available measurements to investigate the relevant fluid flow phenomena occurring and to discuss significant issues related to an accurate prediction of the turbine wall heat transfer.     

Drapage géométrique des compositesGeometrical draping of composite fabrics

This paper presents a study devoted to the composite fabric shaping simulation in finite strain analysis. We introduce a new geometrical approach based on the fishnet method for which the deformation of a fabric mesh element consists in a pure trellis effect. Such a fabric mesh element is then defined by a curved quadrilateral whose edges are geodesic lines with the same length plotted onto the surface to drape. Given three vertices of the fabric mesh element on the surface, we propose an optimization algorithm to define the fourth vertex of the fabric mesh element. This algorithm allows us to drape the surface using an advancing front approach from the data of an initial impact point between the fabric and the surface and the initial fibre directions at this point. A numerical draping simulation example using this approach is given. To cite this article: H. Borouchaki, A. Cherouat, C. R. Mecanique 331 (2003).     

Conjugate Phase Change Heat Transfer in an Inclined Compound Cavity Partially Filled with a Porous Medium: A Deformed Mesh Approach

In this paper, the melting process of a PCM inside an inclined compound enclosure partially filled with a porous medium is theoretically addressed using a novel deformed mesh method. The sub-domain area of the compound enclosure is made of a porous layer and clear region. The right wall of the enclosure is adjacent to the clear region and is subject to a constant temperature of T_c. The left wall, which is connected to the porous layer, is thick and thermally conductive. The thick wall is partially subject to the hot temperature of T_h. The remaining borders of the enclosure are well insulated. The governing equations for flow and heat transfer, including the phase change effects and conjugate heat transfer at the thick wall, are introduced and transformed into a non-dimensional form. A deformed grid method is utilized to track the phase change front in the solid and liquid regions. The melting front movement is controlled by the Stefan condition. The finite element method, along with Arbitrary Eulerian–Lagrangian (ALE) moving grid technique, is employed to solve the non-dimensional governing equations. The modeling approach and the accuracy of the utilized numerical approach are verified by comparison of the results with several experimental and numerical studies, available in the literature. The effect of conjugate wall thickness, inclination angle, and the porous layer thickness on the phase change heat transfer of PCM is investigated. The outcomes show that the rates of melting and heat transfer are enhanced as the thickness of the porous layer increases. The melting rate is the highest when the inclination angle of the enclosure is 45°. An increase in the wall thickness improves the melting rate.

     

Continuum damage models with non-conventional finite element formulations

In recent years, some research effort has been devoted to the development of non-conventional finite element models for the analysis of concrete structures. These models use continuum damage mechanics to represent the physically non-linear behavior of this quasi-brittle material. Two alternative approaches proved to be robust and computationally competitive when compared with the classical displacement finite element implementations. The first corresponds to the hybrid-mixed stress model where both the effective stress and the displacement fields are independently modeled in the domain of each finite element and the displacements are approximated along the static boundary, which is considered to include the inter-element edges. The second approach corresponds to a hybrid-displacement model. In this case, the displacements in the domain of each element and the tractions along the kinematic boundary are independently approximated. Since it is a displacement model, the inter-element boundaries are now included in the kinematic boundary. In both models, complete sets of orthonormal Legendre polynomials are used to define all approximations required, so very effective p-refinement procedures can be implemented. This paper illustrates the numerical performance of these two alternative approaches and compares their efficiency and accuracy with the classical finite element models. For this purpose, a set of numerical tests is presented and discussed.     

INITIALLY TENSIONED ORTHOTROPIC CYLINDRICAL SHELLS CONVEYING FLUID: A VIBRATION ANALYSIS

A linear analysis of the vibratory behaviour of initially tensioned orthotropic circular cylindrical shells conveying a compressible inviscid fluid is presented. The model is based on the three-dimensional nonlinear theory of elasticity and the Eulerian equations. A nonlinear strain–displacement relationship is employed to derive the geometric stiffness matrix due to initial stresses and hydrostatic pressures. Frequency-dependent fluid mass, damping and stiffness matrices associated with inertia, Coriolis and centrifugal forces, respectively, are derived through the fluid–structure coupling condition. The resulting equation governing the vibration of fluid-conveying shells is solved by the finite element method. The free vibration of initially tensioned orthotropic cylindrical shells conveying fluid is investigated; numerical examples are given and discussed.     

3D macrosegregation simulation with anisotropic remeshing

The article presents a three-dimensional coupled numerical solution of momentum, mass, energy and solute conservation equations, for binary alloy solidification. The interdendritic flow in the mushy zone is assumed to obey the Darcy's law. Microsegregation is governed by the lever rule, assuming local equilibrium at phase interfaces. The resulting energy and solute advection–diffusion equations are solved using the Streamline-Upwind/Petrov–Galerkin (SUPG) finite element method. A SUPG-PSPG velocity-pressure formulation is applied for the momentum equation. The full algorithm was implemented in the 3D code THERCAST, together with an anisotropic remeshing method. Two applications have been considered: a small ingot of Pb-48wt%Sn alloy and a large steel ingot. The numerical results of these two cases are presented with the evolution of temperature, liquid velocity, and solute concentration fields during solidification. To cite this article: S. Gouttebroze et al., C. R. Mecanique 335 (2007).     

A finite element model for the simulation of lost foam casting

In this paper, we present a numerical model to simulate the lost foam casting process. We introduce this particular casting first in order to capture the different physical processes in play during a casting. We briefly comment on the possible physical and numerical models used to envisage the numerical simulation. Next we present a model which aims to solve ‘part of’ the complexities of the casting, together with a simple energy budget that enables us to obtain an equation for the velocity of the metal front advance. Once the physical model is established we develop a finite element method to solve the governing equations. The numerical and physical methodologies are then validated through the solution of a two‐ and a three‐dimensional example. Finally, we discuss briefly some possible improvements of the numerical model in order to capture more physical phenomena. Copyright © 2004 John Wiley & Sons, Ltd.     

Extended three-dimensional digital image correlation (X3D-DIC)

A correlation algorithm is proposed to measure full three-dimensional displacement fields in a three-dimensional domain. The chosen kinematic basis for this measurement is based on continuous finite-element shape functions. It is furthermore proposed to account for the presence of strong discontinuities, similarly to extended finite element schemes, with a suited enrichment of the kinematics with discontinuities supported by a (crack) surface. An optimization of the surface geometry is proposed based on correlation residuals. The procedure is applied to analyze one loading cycle of a fatigue-cracked nodular graphite cast iron sample by using computed tomography pictures. Subvoxel crack openings are revealed and measured. To cite this article: J. Réthoré et al., C. R. Mecanique 336 (2008).     

金属结构航天器陨落过程三维瞬态传热有限元算法研究

构建金属桁架结构航天器陨落再入气动热环境有限元传热模型，是准确预测在轨服役期满大型航天器陨落再入解体过程温度分布的关键。本文采用四节点四面体单元对空间进行离散，依据泛函理论，将传热控制方程离散为代数方程组；利用有限单元法总体合成得到具有对称正定、高度稀疏和非0元素分布的规则性刚度矩阵，发展一维变带宽压缩存贮技术，有效解决大型稀疏矩阵的数据存贮问题；为有效抑制求解过程出现的温度在时间和空间上的振荡问题，发展集中热容矩阵系数处理方法，将热容矩阵的同行或同列元素相加代替对角线元素，使非对角线元素化为0，构造求解三维瞬态温度场的两点向后差分格式、Crank-Nicolson格式和Galerkin格式。通过对正方体瞬态传热计算验证分析，在相同条件下，采用以上三种格式均可获得一致稳定的温度解，并得到与现有ANSYS有限元软件较为吻合的计算结果，验证了所建立三维瞬态传热有限元计算模型的准确可靠性。在此基础上，对铝合金低轨航天器薄壳结构进行了传热计算，给出了类天宫飞行器两舱体陨落飞行107.5 km~90 km不同高度的瞬态温度分布，为这类寿命末期航天器陨落再入解体预报提供理论支撑与可计算模型。     

Champ de vitesse dans un échangeur à vortex en régime turbulentHeat exchanger velocity field with turbulent inlet condition

We consider the isothermal flow through a cylindrical flat chamber, a model of some particular heat exchanger, for which LDV measurements and a numerical simulation have been performed. Experimental results show the establishment of an important vortex zone, the secondary flow extending all along the chamber radius. This observation leads to an expected significant increase of the fluid mixing. Results issued from the numerical simulation appear to be in close agreement with experimental data. Nevertheless, the k–ε model used here must be improved to obtain a better approach near the vortex centre. To cite this article: S. Petitot et al., C. R. Mecanique 330 (2002) 593–599.