Parameters optimization of selected casting processes using teaching–learning-based optimization algorithm

In the present work, mathematical models of three important casting processes are considered namely squeeze casting, continuous casting and die casting for the parameters optimization of respective processes. A recently developed advanced optimization algorithm named as teaching–learning-based optimization (TLBO) is used for the parameters optimization of these casting processes. Each process is described with a suitable example which involves respective process parameters. The mathematical model related to the squeeze casting is a multi-objective problem whereas the model related to the continuous casting is multi-objective multi-constrained problem and the problem related to the die casting is a single objective problem. The mathematical models which are considered in the present work were previously attempted by genetic algorithm and simulated annealing algorithms. However, attempt is made in the present work to minimize the computational efforts using the TLBO algorithm. Considerable improvements in results are obtained in all the cases and it is believed that a global optimum solution is achieved in the case of die casting process.     

Singular finite elements for the sudden-expansion and the die-swell problems

The singular finite element method is used to solve the sudden-expansion and the die-swell problems in order to improve the accuracy of the solution in the vicinity of the singularity and to speed up the convergence. The method requires minor modifications to standard finite element schemes, and even coarse meshes give more accurate results than refined ordinary finite element meshes. Improved normal stress results for the sudden-expansion problem have been obtained for various Reynolds numbers up to 100 using the singular elements constructed for the creeping flow problem. In addition, the normal stresses at the walls appear to be insensitive to the singularity powers used in the construction of the singular basis functions. The die-swell problem is solved using the singular elements constructed for the stick–slip problem. The singular elements accelerate the convergence of the free surface dramatically.     

Dynamic Theory of Die Swell for Entangled Polymeric Liquids in Tube Extrusions: New Set of Equations for the Growth and Ultimate Extrudate Swelling Ratios under the Free States

A new dynamic theory of die swell for entangled polymeric liquids in a steady simple shear °ow is proposed which can be used to predict the correlation of the time-dependent and time-independent extrudate swelling behaviors to the molecular parameters of polymers and the operational variables. The theory is based on the O-W-F constitutive equation and the free recovery from Poioeuille flow with different ratios. Experimentsshow that the magnitudes of the simple shear in the steady simple shear flow may be resolved into the free recoil resulting from the recoverable elastic strains and the viscous heating resulting from the unrecoverable viscoelastic strains. For distinguishing the recoil from the viscous heating, a partition function and twoexponential fractions of conformation for the recoil and the viscous heating were defined. Thus the instantaneous, delayed and ultimate recoverable strain, and recoil in the free recovery were correlated to the partition function, the fraction of recoverable conformation, the molecular parameters, and the operational variables. Also the dynamics of the growth equation on the delayed viscoelastic strain and the delayed recoil in freestate were deduced. After introducing the condition of uniform two dimensional extensions, the definition ofswell ratio and the operational variables into the above correlation expressions and growth equations, then the correlations of the delayed extrudate swelling effect and the ultimate extrudate swelling effects to the molecular parameters and the operational variables were derived. Finally, two new sets of equations on the growth variables and ultimate extrudate swelling ratios under the dynamic and equilibrium states were also deduced from this dynamic theory of die swell. The first set of equations on the ultimate extrudate swelling ratio under the free and equilibrium states was verified by HDPE experimental data at two temperatures and different operational variables. The second set of equations on the growth extrudate swelling ratios under free and dynamic states was verified by PBD experimental data with different molecular weights and different operational variables. An excellent agreement is obtained, which shows that the two sets of equations for the growth and ultimate extrudate swelling ratios can be used directly to predict the correlation of extrudate swelling ratios to the molecular parameters and the operational variables.     

缠结高分子液体在管中挤出胀大动力学理论：一组新的增长和最终挤出胀大比方程

基于O-W-F本构方程和自由回复机制，从Poioeuille流出发建立了一种新的缠结高分子液体挤出胀大动力学理论，该理论能有效地预测高分子流体的动静态挤出胀大行为同高分子粘弹性参数和成型条件间的相关性. 基于稳态剪切量可分解为自由“回复线团”和“不可回复热耗”两部分事实，定义了一个稳态剪切下自由“回复线团”和“不可回复热耗”的配分函数和它们两者间分配指数上可回复和不可回复构象分数，从而在理论上得到了瞬时、推迟和最终三者可回复形变量和可回复线团量同配分函数、分配指数上可回复构象分数、分子粘弹性参数和成型条件     

Study on the melt entry flow characteristics in axisymmetric dies with abrupt contraction by a visualization technique

The die entry characteristics of low density polyethylenes (LDPE) were studied using a 45 mm diameter single-screw extruder. The extruder incorporated a “transparent” die to enable direct visualization to be performed. With the addition of a small percent of red colour masterbatch into the main polymer bulk, melt circulation near the die entry at the wall was clearly observed. The dynamic behaviour of the polymer melt was recorded by a digital video recorder. Upon replaying the films, detailed qualitative and quantitative analysis of the flow characteristics was made. The die entry performance was defined by the dimensionless vortex size which was found to be most susceptible to the contraction ratio of a die. It was found that temperature and length to diameter ratio had little or no effects on the dimensionless vortex size which, in turn, may be estimated by either of the two correlations (one based on theory whereas the other was obtained from curve-fitting) developed.     

A mixed finite element scheme for viscoelastic flows with XPP model

A mixed finite element formulation for viscoelastic flows is derived in this paper, in which the FIC （finite incremental calculus） pressure stabilization process and the DEVSS （discrete elastic viscous stress splitting） method using the Crank-Nicolson-based split are introduced within a general framework of the iterative version of the fractional step algorithm. The SU （streamline-upwind） method is particularly chosen to tackle the convective terms in constitutive equations of viscoelastic flows. Thanks to the proposed scheme the finite elements with equal low-order interpolation approximations for stress-velocity-pressure variables can be successfully used even for viscoelastic flows with high Weissenberg numbers. The XPP （extended Pom-Pom） constitutive model for describing viscoelastic behaviors is particularly integrated into the proposed scheme. The numerical results for the 4：1 sudden contraction flow problem demonstrate prominent stability, accuracy and convergence rate of the proposed scheme in both pressure and stress distributions over the flow domain within a wide range of the Weissenberg number, particularly the capability in reproducing the results, which can be used to explain the ＂die swell＂ phenomenon observed in the polymer injection molding process.     

Dynamic Theory of Die Swell for Entangled Polymeric Liquids in Tube Extrusion: Correlations of Total and Ultimate Extrudate Swell Effects to Growth Time,Shear Stress and Aspect Ratio Under the Free States

The dynamic theory of die swell deduced in a previous paper was extensively applied to study the xtrudate swelling behaviors of two entangled polymeric liquids (HDPE and PBD) in a simple shear flow at steady shear stress. The mechanism and dynamics for the recoils and the recoveries of viscoelastic strains in the extrudate were investigated under the free recovery and dynamic states. It was found that in the course of recovery the free recoil and the growth of die swell in the extrudate may be divided into two recovery regions (instantaneous and delayed regions) and three growth stages (instantaneous, delayed, and ultimate extrudate swelling stages). The free recoil and the extrudate swelling behaviors may be expressed as a function of shear stress. The correlations of instantaneous, delayed, total and ultimate extrudate swell effects to the molecular parameters and the operational variables in the simple shear flow at steady shear stress were derived from the dynamic theory of die swell. Also, two sets of new universal equations on the total extrudate swelling effect (TESE) and ultimate extrudate swelling effect (UESE) were deduced. The first is the universal equation of the logarithmic correlation between the TESE and the growth time under the free and dynamic states; the second is the universal equation of the logarithmic correlation between the UESE and the operational variables under the free and equilibrium states. The first equation was verified by experimental data of PBD with different molecular weights at different operational variables. The second equation was verified by experimental data of HDPE at two temperatures and different operational variables. An excellent agreement result was obtained. The excellent agreement shows that the two universal equations can be used directly to predict the correlations of the TESE and UESE to the growth time, the molecular parameters, and the operational variables under the dynamic and equilibrium states.     

DEM simulations of die filling during pharmaceutical tabletting

The flow behaviour of powders from a stationary shoe into a moving die, which mimics the die filling process in a rotary tablet press, was analysed using a discrete element method （DEM）, in which 2D irregular shaped particles were considered. The influence of the particle shape, size and size distribution, the number of particles used in the simulation, the initial height of powder bed in the shoe, and the filling speed on the average mass flow rate and the critical filling speed （the highest speed at which the die can be completely filled） were explored. It has been found that a maximum flow rate is obtained at the critical filling speed for all systems investigated and poly-disperse systems have higher mass flow rates and higher critical filling speeds than mono-disperse systems. In addition, the powder with particles which can tessellate generally has a lower filling rate and a lower critical titling speed.     

稀土氧化物对堆焊金属抗开裂性能的影响

采用金相和电镜等手段对堆焊裂纹形貌进行了观察,并研究了稀土氧化物对堆焊金属抗开裂性能及塑、韧性的影响。结果表明,堆焊金属中的开裂形式为结晶裂纹和淬硬裂纹,加入稀土氧化物能提高堆焊金属的抗开裂性能。