Modelling and simulation of moving interfaces in gas-assisted injection moulding process

The mathematical models of gas–liquid two-phase flow are introduced, in which the multi-mode eXtended Pom–Pom (XPP) model is selected to predict the viscoelastic behavior of polymer melt. The gas-penetration process is simulated using Level Set/SIMPLEC methods, which can capture the moving interfaces at different time, including the gas–melt interface and the melt front. The physical features such as velocity, temperature and elasticity are described at different time. The influences of gas delay time and injection pressure on gas-penetration time and penetration length are analyzed. The numerical results show that the Level Set/SIMPLEC methods can precisely trace the two moving interfaces in gas-penetration process, the fractional coverage increases at very low Deborah numbers, while at higher Deborah numbers the fractional coverage decreases, and the penetration length is affected significantly by gas delay time and injection pressure.     

A prediction of the acoustical properties of induction cookers based on an FVM–LES-acoustic analogy method

The FVM–LES-acoustic analogy method (FVM–LES-AAM), which is a hybrid prediction technique for the acoustical property computation, is presented and performed in this paper. The FVM–LES-AAM was developed by combining the finite volume method (FVM), the large eddy simulation (LES), and the Ffowcs Williams-Hawkings analogy algorithm (FWH-AA). To predict the acoustical properties of induction cookers, the FVM is used for discretizing the calculation field and building numerical equations, and the LES and FWH-AA are performed for computing the sound sources and predicting the far-field sound, respectively. Using the FVM with the unstructured grids method to discretize the control equation of Navier–Stokes was introduced for illuminating the above numerical simulation procedure. To prove the FVM–LES-AAM method is feasible for predicting the acoustical property of induction cookers, the simulated results were compared with some measured experimental data. The comparisons suggest that the hybrid method is accurate and reliable for the aeroacoustics analysis of induction cookers. Considering the temperature performance, furthermore, some new configurations for the noise reduction of induction cookers were designed, simulated, and discussed. The FVM–LES-AAM prediction technique shows promise as a feasible and computationally affordable approach for not only noise analysis of induction cookers, but also for other aeroacoustics problems in engineering.     

Single phase limit for melting nanoparticles

The melting of a spherical or cylindrical nanoparticle is modelled as a Stefan problem by including the effects of surface tension through the Gibbs–Thomson condition. A one-phase moving boundary problem is derived from the general two-phase formulation in the singular limit of slow conduction in the solid phase, and the resulting equations are studied analytically in the limit of small time and large Stefan number. Further analytical approximations for the temperature distribution and the position of the solid–melt interface are found by applying an integral formulation together with an iterative scheme. All these analytical results are compared with numerical solutions obtained using a front-fixing method, and are shown to provide good approximations in various regimes. The inclusion of surface tension, which acts to decrease the melting temperature as the particle melts, is shown to accelerate the melting process. Unlike the classical one-phase Stefan problem without surface tension, the solid–melt interface exhibits blow-up at some critical radius of the particle (which for metals is of the order of a few nanometres), a phenomenon that has been observed experimentally. An interesting feature of the model is the prediction that surface tension drives superheating in the solid particle before blow-up occurs.     

Modeling dendritic solidification of Al–3%Cu using cellular automaton and phase-field methods

We compared a cellular automaton (CA)–finite element (FE) model and a phase-field (PF)–FE model to simulate equiaxed dendritic growth during the solidification of cubic crystals. The equations of mass and heat transports were solved in the CA–FE model to calculate the temperature field, solute concentration, and the dendritic growth morphology. In the PF–FE model, a PF variable was used to identify solid and liquid phases and another PF variable was considered to determine the evolution of solute concentration. Application to Al–3.0 wt.% Cu alloy illustrates the capability of both CA–FE and PF–FE models in modeling multiple arbitrarily-oriented dendrites in growth of cubic crystals. Simulation results from both models showed quantitatively good agreement with the analytical model developed by Lipton–Glicksman–Kurz (LGK) in the tip growth velocity and the tip equilibrium liquid concentration at a given melt undercooling. The dendrite morphology and computational time obtained from the CA–FE model are compared to those of the PF–FE model and the distinct advantages of both methods are discussed.     

Extension of the Lamé–Gadolin problem for large deformations and its analytical solution

The formulation and solution of the axisymmetric static problem of the stress-strain state of two hollow circular elastic cylinders, one of which is predeformed and inserted into the other cylinder, is considered in the case of large plane deformations (an extension of the Lamé–Gadolin problem to large deformations). Using the theory of the superposition of large deformations, an exact analytical solution of the static problem for cylinders made of incompressible Treloar and Bartenev–Khazanovich materials is obtained, including the case when the cylinders are made of dissimilar materials. An analytical solution is obtained in parametric form for a compressible Blatz–Ko material. Non-linear effects are investigated.     

Numerical optimisation for induction heat treatment processes

This paper aims at introducing new approaches for designing and optimising induction heat treatment processes. Although the final objectives of induction heating processes may deal with some specific mechanical or metallurgical properties for manufactured parts, we shall primarily focus here on achieving an accurate control of temperature distribution and evolution in the Heat Affected Zone (HAZ). This objective can be formalised as a classical optimisation problem: we seek to minimise a cost function which measures the difference between computed and goal temperatures – along with some constraints on process parameters. We deal here with both zero-order algorithms – using a method based on Efficient Global Optimization algorithm which is an optimisation procedure assisted by a meta model – as well as first-order algorithms. These algorithms have been coupled with 2-D and 3-D finite element models developed in our laboratory; this model is based on a coupling procedure between Maxwell equations and heat transfer models, and has been extended to mechanical and metallurgical computations.     

An atomic-continuum multiscale modeling approach for interfacial thermal behavior between materials

The aim of this paper is to provide a systematic method to perform interfacial thermal behavior between materials. A multiscale modeling method is proposed to investigate the interfacial thermal properties about copper nano interface structure. The interface stress element (ISE) method is set as a coupling button to a span-scale model combined with molecular dynamics (MD) and finite element (FE) methods. The handshake regions can simulate the structure transfer properties between the transition with MD and ISE, ISE and FE. The multiscale model is used to calculate the interfacial thermal characters under different temperatures. Some examples about numerical experiments with copper materials demonstrate the performance of MD–ISE–FE multiscale model is more successful compared with the approach applying MD–FE model. The results indicate that the accuracy of the MD–ISE–FE model is higher than that of MD–FE mode. This investigation implies a potential possibility of multiscale analysis from atomic to continuum scales.     

A cellular automaton technique for modelling of a binary dendritic growth with convection

A two-dimensional model for the simulation of a binary dendritic growth with convection has been developed in order to investigate the effects of convection on dendritic morphologies. The model is based on a cellular automaton (CA) technique for the calculation of the evolution of solid/liquid (s/l) interface. The dynamics of the interface controlled by temperature, solute diffusion and Gibbs–Thomson effects, is coupled with the continuum model for energy, solute and momentum transfer with liquid convection. The solid fraction is calculated by a governing equation, instead of some approximate methods such as lever rule method [A. Jacot, M. Rappaz, Acta Mater. 50 (2002) 1909–1926.] or interface velocity method [L. Nastac, Acta Mater. 47 (1999) 4253; L. Beltran-Sanchez, D.M. Stefanescu, Mat. and Mat. Trans. A 26 (2003) 367.]. For the dendritic growth without convection, mesh independency of simulation results is achieved. The simulated steady-state tip velocity are compared with the predicted values of LGK theory [Lipton, M.E. Glicksmanm, W. Kurz, Metall. Trans. 18(A) (1987) 341.] as a function of melt undercooling, which shows good agreement. The growth of dendrite arms in a forced convection has been investigated. It was found that the dendritic growth in the upstream direction was amplified, due to larger solute gradient in the liquid ahead of the s/l interface caused by melt convection. In the isothermal environment, the calculated results under very fine mesh are in good agreement with the Oseen–Ivanstov solution for the concentration-driven growth in a forced flow.     

1-Dimensional representations and parabolic induction for W-algebras

A W-algebra is an associative algebra constructed from a reductive Lie algebra and its nilpotent element. This paper concentrates on the study of 1-dimensional representations of W-algebras. Under some conditions on a nilpotent element (satisfied by all rigid elements) we obtain a criterium for a finite dimensional module to have dimension 1. It is stated in terms of the Brundan–Goodwin–Kleshchev highest weight theory. This criterium allows to compute highest weights for certain completely prime primitive ideals in universal enveloping algebras. We make an explicit computation in a special case in type E₈. Our second principal result is a version of a parabolic induction for W-algebras. In this case, the parabolic induction is an exact functor between the categories of finite dimensional modules for two different W-algebras. The most important feature of the functor is that it preserves dimensions. In particular, it preserves one-dimensional representations. A closely related result was obtained previously by Premet. We also establish some other properties of the parabolic induction functor.     

A numerical analysis of solid–liquid phase change heat transfer around a horizontal cylinder

A numerical study is conducted to analyze the melting process around a horizontal circular cylinder in the presence of the natural convection in the melt phase. Two boundary conditions are investigated one of constant wall temperature over the surface of the cylinder and the other of constant heat flux. A numerical code is developed using an unstructured finite-volume method and an enthalpy porosity technique to solve for natural convection coupled to solid–liquid phase change. The validity of the numerical code used is ascertained by comparing our results with previously published results.     

High performance robust linear controller synthesis for an induction motor using a multi-objective hybrid control strategy

A robust induction motor control should provide the desired performance in the face of both plant model and controller model uncertainty. In a recent work, Bottura and co-workers, using the field orientation principle, introduced a representation of a nonlinear time-varying induction motor model that admits robust induction motor controller synthesis in the linear _H∞$H_{\infty }$ framework. The present work considers the use of the approach of Bottura et al. for attaining robust performance of the main operating modes–tracking and disturbance rejection–of an induction motor control system under implementation constraints on the control signal magnitude. This approach requires two distinct mode-specific controllers with gains that cannot be bridged without considerable performance degradation. To address this problem, a multi-objective hybrid control design methodology is developed that employs the corresponding mode-specific controller in each mode, and organizes a rapid and smooth steady-state switching, or transfer, between these controllers to permit sequencing of the operating modes, as necessary. Simulation shows that the technique proposed yields controllers with performance minimally affected by an imprecise modeling of an induction motor, as well as a reduced cost controller implementation throughout the entire induction motor operating sequence.     

Numerical analysis of quenching – Heat conduction in metallic materials

Metallic materials present a complex behavior during heat treatment processes. In a certain temperature range, change of temperature induces a phase transformation of metallic structure, which alters physical properties of the material. Indeed, measurements of specific heat and conductivity show strong temperature-dependence during processes such as quenching of steel. Several mathematical models, as solid mixtures and thermal–mechanical coupling, for problems of heat conduction in metallic materials, have been proposed. In this work, we take a simpler approach without thermal–mechanical coupling of deformation, by considering the nonlinear temperature-dependence of thermal parameters as the sole effect due to those complex behaviors. The above discussion of phase transformation of metallic materials serves only as a motivation for the strong temperature-dependence as material properties. In general, thermal properties of materials do depend on the temperature, and the present formulation of heat conduction problem may be served as a mathematical model when the temperature-dependence of material parameters becomes important. For this mathematical model we present the error estimate using the finite element method for the continuous-time case.     

Curved domain walls dynamics driven by magnetic field and electric current in hard ferromagnets

The propagation of curved domain walls in hard ferromagnetic materials is studied by applying a reductive perturbation method to the generalized Landau–Lifshitz–Gilbert equation. The extended model herein considered explicitly takes into account the effects of a spin-polarized current as well as those arising from a nonlinear dissipation.     

Using the Black–Derman–Toy interest rate model for portfolio optimization

No-arbitrage interest rate models are designed to be consistent with the current term structure of interest rates. The diffusion of the interest rates is often approximated with a tree, in which the scenario-dependent fair price of any security is calculated as the present value of the risk-neutral expectation by backward induction. To use this tree in a portfolio optimization context it is necessary to account for the so-called “market price of risk”. In this paper we present a method to change the conditional probabilities in the Black–Derman–Toy model to the physical (or real) measure, including the market price of risk, and explore the economic implications for expected spot rates and for expected bond returns.     

Numerical evaluation of zirconium reinforced aluminium matrix composites for sustainable environment

Due to the momentous advantages of composite materials, recent years many studies focused on reinforcing different new materials to the existing ones to improve their conventional strength and life time within the concern of application status. In the row, reinforcements on Al6061 become a fancy topic among researchers due to its wide applications including automobiles, yachts, electrical fittings and so on. This study continues this innovation by reinforcing three different reinforcement materials including zirconia (ZrO₂), zirconia + aluminium oxide (ZrO₂ +Al₂O₃) and fused zirconia aluminum (40FZA). These three reinforcing materials are included with the proposition of varying particle reinforcements as 5, 10 and 15%. The testing specimens were experimented to explore its mechanical, wear and corrosion behavior. Further the experimental results are given as inputs to the numerical analysis, PROMETHEE. By combining the experimental and numerical methodologies the reliability of the results were improved. However, from this study it can be evident that inclusion of 15% particle reinforcement of zirconia fused alumina in Al6061 provides greater strength, toughness, high resistance to wear and corrosion on both experimental and numerical analysis. There is ample room that this proposed material inclusion be a better option for the reinforcement of Al6061 among available alternatives for sustainable development.

     

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.     

Energy estimates for continuous and discretized electro-reaction–diffusion systems

We consider electro-reaction–diffusion systems consisting of continuity equations for a finite number of species coupled with a Poisson equation. We take into account heterostructures, anisotropic materials and rather general statistic relations.     

Mathematical Modeling of Czochralski Type Growth Processes for Semiconductor Bulk Single Crystals

This paper deals with the mathematical modeling and simulation of crystal growth processes by the so-called Czochralski method and related methods, which are important industrial processes to grow large bulk single crystals of semiconductor materials such as, e. g., silicon (Si) or gallium arsenide (GaAs) from the melt. In particular, we investigate a recently developed technology in which traveling magnetic fields are applied in order to control the behavior of the turbulent melt flow. Since numerous different physical effects like electromagnetic fields, turbulent melt flows, high temperatures, heat transfer via radiation, etc., play an important role in the process, the corresponding mathematical model leads to an extremely difficult system of initial-boundary value problems for nonlinearly coupled partial differential equations. In this paper, we describe a mathematical model that is under use for the simulation of real-life growth scenarios, and we give an overview of mathematical results and numerical simulations that have been obtained for it in recent years.     

A Hyperbolic Heat Transfer Problem with Phase Changes

There is a large literature on hyperbolic heat-transfer problems,and a few investigators have studied phase-change or melt problemsfor materials governed by such systems. Most formulations ofmelt problems for hyperbolic models insist on continuity ofthe temperature across the melt interface, and a number of investigatorshave observed that this insistence leads to mathematical difficulties.In this paper an alternative model is explored, where continuityof the temperature at the melt interface is not imposed. Instead,we insist that the relaxation process describing the relationbetween heat flux and temperature gradient be interpreted asa conservation equation that must hold across a melt interface.With this formulation, we are led to a solvable problem withdesirable asymptotic properties.     

Numerical estimation of the thermal expansion of lamellar single domains in metal/ceramic composites

A porous ceramic preform, the pore structure of which is created via a freeze-casting technique, is infiltrated with a metal melt via sqeeze-casting. The microstructure of the obtained metal/ceramic composites has lamellar domains with geometrical characteristics which are dependent on the manufacturing parameters. The aim of our study is to predict the coefficients of thermal expansion of single domains of parallel Al₂O₃ platelets embedded in Al. For this purpose, a homogenization procedure was employed for microstructure based finite element and micromechanical modeling. (© 2010 Wiley-VCH Verlag GmbH & Co. KGaA, Weinheim)