颗粒材料中致密波结构研究

采用一维两相流模型与相应颗粒构形应力函数,研究了致密波的形成及其结构．用简化两相流模型系统地讨论致密波对有关因素的依赖关系．分析指出：小于基体材料音速的致密波仅能在非理想颗粒材料中存在,从波前到波后,所有状态物理量光滑过渡．大于基体材料音速的致密波,波头可能存在间断．应力函数与致密粘性确定后,致密波速度决定致密波结构、宽度、终态压实度．采用一维两相流模型模拟了活塞驱动颗粒床形成致密波这一动态过程．用线方法（MOL）对该方程组求数值解．计算表明,经过短暂的非稳态过程,颗粒床中形成一稳态致密波．分析了活塞速度与初始孔隙率对致密波结构的影响,并对简化两相流模型与两相流模型的计算结果进行了对比．     

Comparison of roller-spreading and blade-spreading processes in powder-bed additive manufacturing by DEM simulations

The roller-spreading and blade-spreading are main powder spreading methods in powder-bed additive manufacturing. The discrete element method was introduced to simulate nylon powder spreading by both roller and blade spreaders. The two spreading processes were compared from several aspects including particle flow behavior, particle contact forces, forces exerted on spreaders, particle segregation and powder layer density. It is found that powder spreading methods mainly affect the movement trajectory of particles, particle contact forces and forces exerted on spreaders. Complicated dispersion and circulation movement of particles occur inside the powder pile by roller-spreading, while particles have relatively weak dispersion by the blade-spreading. The normal force applied to the roller introduces a compacting effect on the powder pile and creates strong force chains that distribute uniformly in the powder pile. Therefore, the powder bed with higher density can be obtained by roller-spreading in thicker powder layer due to the compacting effect. The blade spreader sustains tangential force mainly, so the blade-spreading process limits its application to thicker powder layer. As the powder layer thickness increases, the roller-spreading is more sensitive to segregation index than that of the blade-spreading. The comprehensive comparison of two spreading processes provides criteria for selecting spreading methods.     

选区激光熔化成形区粗糙表面对铺粉质量的影响:离散元模拟

选区激光熔化中, 铺粉质量会极大地影响产品的最终质量. 然而, 成形区粗糙表面对铺粉质量影响的研究较少. 因此, 本文以成形区粗糙表面作为新的铺粉基板, 通过离散元法, 研究铺粉过程中成形区的表面形貌和工艺参数对铺粉质量的影响, 并分析铺粉过程中金属粉末在成形区粗糙表面的颗粒动力学和颗粒沉积机制. 结果表明, 将激光扫描方向与铺粉方向旋转一定角度可有效提高粉末层质量, 增加铺粉层厚可减小成形区粗糙表面对铺粉质量的影响. 减小搭接率可提高成形区对颗粒的滞留能力, 从而使更多的颗粒沉积在成形区, 提高粉床填充密度, 但是粉末颗粒会与成形区的粗糙表面碰撞, 产生颗粒迸溅现象. 此外, 铺粉过程中, 由于成形区粗糙度的增大, 成形区粗糙表面上的粉堆产生的强力链、力拱数量多于表面光滑的成形区. 在滚轮作用下, 力拱断裂导致颗粒重新排列, 形成致密的粉末层. 在成形区边界处, 力拱的产生会最终导致边界处的粉末层出现空斑缺陷. 本研究有助于通过优化工艺提高粉床质量.      

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 filling speed.     

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.     

Spreading dynamics of droplet on an inclined surface

A three-dimensional unsteady theoretical model of droplet spreading process on an inclined surface is developed and numerically analyzed to investigate the droplet spreading dynamics via the lattice Boltzmann simulation. The contact line motion and morphology evolution for the droplet spreading on an inclined surface, which are, respectively, represented by the advancing/receding spreading factor and droplet wetted length, are evaluated and analyzed. The effects of surface wettability and inclination on the droplet spreading behaviors are examined. The results indicate that, dominated by gravity and capillarity, the droplet experiences a complex asymmetric deformation and sliding motion after the droplet comes into contact with the inclined surfaces. The droplet firstly deforms near the solid surface and mainly exhibits a radial expansion flow in the start-up stage. An evident sliding-down motion along the inclination is observed in the middle stage. And the surface-tension-driven retraction occurs during the retract stage. Increases in inclination angle and equilibrium contact angle lead to a faster droplet motion and a smaller wetted area. In addition, increases in equilibrium contact angle lead to a shorter duration time of the middle stage and an earlier entry into the retract stage.     

激光选区熔化增材制造中的粉体热动力学行为

激光选区熔化(SLM)可以直接成形近全致密、性能接近锻件的复杂结构金属零件, 是金属增材制造(3D打印)领域的热点技术之一. SLM成形过程中粉末颗粒的热/动力学行为复杂, 与零件成形缺陷及力学性能紧密相关. 本文介绍了离散单元法(DEM)与计算流体力学(CFD)联合建模在SLM中的创新应用, 结合粉末床原位测试及成形在线监测, 探索SLM粉末铺设和粉末床熔融两个工艺环节的复杂粉体热/动力学行为机制. 研究发现, 粉末铺设过程中: 粉体的黏结效应、壁面效应和渗流效应3种机制相互竞争、共同支配粉末动力学行为并最终决定粉末床铺设质量. 粉末床熔融过程中: 熔池喷发的高温金属蒸汽带动环境保护气体形成内旋涡流, 由此驱动散体粉末形成复杂流固耦合运动, 导致粉末床飞溅与剥蚀现象; 热浮力效应对粉末运动不起主导作用. 文中提出了DEM-CFD双向动态耦合模型, 可以充分考虑离散粉末与熔池蒸发气体之间的热力耦合作用, 为SLM粉体熔融热/动力学行为的仿真模拟提供了一种新途径.      

Numerical investigation into the influence of the punch shape on the mechanical behavior of pharmaceutical powders during compaction

During the production of pharmaceutical tablets using powder compaction, certain common problems can occur, such as sticking, tearing, cutting, and lamination. In the past, the compressibility of the powder was calculated only along the axis of the device; consequently, critical areas of the material throughout the volume could not be identified. Therefore, finite element method （FEM） can be used to predict these defects in conjunction with the use of an appropriate constitutive model. This article summarizes the current research in the field of powder compaction, describes the Drucker-Prager Cap model calibration procedure and its implementation in FEM, and also examines the mechanical behavior of powder during compaction. In addition, the mechanical behavior of pharmaceutical powders in relation to changes in friction at the wall of the system is examined, and the dependence of lubrication effect on the geometry of the compaction space is also investigated. The influence of friction on the compaction process for the flat-face, fiat-face radius edge, and standard convex tablets is examined while highlighting how the effects of friction change depending on the shape of these tablets.     

A new constitutive model for shear banding instability in metallic glass

Inelastic deformation of metallic glass is through shear banding, characterized by significantly localized deformation and emerged expeditiously under certain stress state. This study establishes a new constitutive model addressing the physical origin of the shear banding. In the modeling, the atomic structural change and the free volume generation are embodied by the plastic shear strain and the associated dilatation. The rugged free energy landscape is adopted to naturally reflect the rate-independent flow stress and flow serrations. Based on this, the conditions for the onset of shear banding instability are established, which enables the explicit calculation of the shear band inclination angle and its extension speed. The study concludes that shear band angle is significantly influenced by the diltancy factor and pressure sensitivity, that a shear band does not increase its thickness once emanated from a deformation unit, that the spreading speed of a shear band is intersonic, and that more shear bands, which lead to higher ductility, can be induced by high strain rates or by the introduction of a second material phase. The analysis also demonstrates that the ductility of metallic glass depends on the sample geometry and/or the stress state.     

Two-phase flow in inclined tubes with specific reference to condensation: A review

Tilting influences the flow patterns and thus the heat transfer and pressure drop during condensation in smooth tubes. However, few studies are available on diabatic two-phase flows in inclined tubes. The purpose of the present paper is to review two-phase flow in inclined tubes, with specific reference to condensation. Firstly, the paper reviews convective condensation in horizontal tubes. Secondly, an overview is given of two-phase flow in inclined tubes. Thirdly, a review is conducted on condensation in inclined tubes. It is shown for convective condensation in inclined tubes that the inclination angle influences the heat transfer coefficient. The heat transfer coefficient can be increased or decreased depending on the experimental conditions, and especially the flow pattern. Under certain conditions, an inclination angle may exist, which leads to an optimum heat transfer coefficient. Furthermore, this paper highlights the lack of experimental studies for the prediction of the inclination angle effect on the flow pattern, the heat transfer coefficient and the pressure drop in two-phase flows during phase change.     

尼龙粉末在SLS预热温度下的离散元模型参数确定及其流动特性分析

尼龙粉末是增材制造中常用的粉体材料,温度对其流动性有重要影响. 探索尼龙粉末增材制造预热温度下的流动性是研究选择性激光烧结(selective laser sintering, SLS)工艺中粉体铺展成形的基础. 选取SLS技术中的尼龙粉末为原材料,采用离散元数值方法,研究尼龙粉末的流动行为,是增材制造工艺数值模拟和铺粉工艺优化的研究热点. 以Hertz-Mindlin模型为基础,基于Hamaker理论模型和库伦定律,在尼龙粉末的接触动力学模型中引入范德华力和静电力,建立预热温度下尼龙粉末流动的离散元模型(discrete element method, DEM),通过对比相应实验结果,标定了该模型的参数. 对加热旋转圆筒中尼龙粉末流动过程进行了DEM数值模拟,校核了所建模型的正确性,并研究了粉体粒径分布对尼龙粉末流动特性的影响规律. 研究表明,尼龙粉末黏附力是静电力与范德华力的共同作用结果;随着粉体粒径的增大,尼龙粉末崩塌角增大,流动性增强;相对于高斯粒径分布,粒径均匀分布的尼龙粉末颗粒流动性更强. 研究结果可指导SLS中铺粉工艺的优化.      

Study of particle rearrangement during powder compaction by the Discrete Element Method

This paper presents simulations of cold isostatic and closed die compaction of powders based on the Discrete Element Method. Due to the particulate nature of powders, densification of the compact proceeds both through the plastic deformation at the particle contact and the mutual rearrangement of particles. The relative weight of each mechanism on the macroscopic deformation process depends on the contact law, the relative density, and the type of stress exerted on the particles (shear or pressure). 3D computer simulations have been carried out to investigate the role of these parameters on the deformation mechanisms of powder compacts. The effect of rearrangement is studied by comparing simulations that use a homogeneous strain field solution for which local rearrangement is omitted and simulations that include local rearrangement. It is shown that local rearrangement has some effect on average quantities such as the average coordination number, the average contact area and the macroscopic stress. The effect on averaged quantities is much stronger for closed die compaction than for isostatic compaction. However the main effect of local rearrangement is to widen the distribution of the parameters that define the contact (contact area in particular). The results of these simulations are compared to available experimental data and to statistical models that use a homogeneous strain field assumption.     

中心点火火焰在药床中传播规律的试验研究

为了研究中心点火管火焰在药床中的传播规律,设计了可视化模拟试验平台,开展了不同点火药量、不同装药结构的中心点传火试验。采用高速图像采集系统记录了中心点火管火焰在药床中的传播过程,采用瞬态压力记录仪记录膛内压力的时空变化。结果表明,点火药量为20 g时,出火时间为0.6 ms;点火药量为30 g时,出火时间为1.5 ms;杆状装药床的传火时间平均为2.2 ms,粒状装药床的传火时间平均为3.4 ms,而杆粒混装药床的传火时间为3.1 ms。可见,点火药量对药床出火时间影响显著,较大的点火药量导致药床出火时间延长;不同装药床结构传火性能差异较大,单一杆状装药床传火性能优于单一粒状装药和杆粒混装药床,并且粒状装药床易形成气体壅塞,膛内会出现明显的压力波动现象;根据火焰传播时序位置点,利用一阶指数衰减函数拟合建立了火焰传播过程数学模型,拟合优度大于0.98。     

稠密颗粒床中点火传火过程的两维两相流数值模拟

本文结合火炮工程背景,建立伴随化学反应的稠密颗粒群气固两相非定常两维轴对称流和点火器内的非定常一维两相流数学模型,并考虑点火器对主装药床的耦合作用。采用MacCormack两步差分格式,模拟点火传火过程中火焰传播及其物理量沿轴向和径向变化规律。部分计算结果与实验结果相吻合。发现点火开始阶段存在明显的径向效应,当火焰波传到固壁后,轴向流占主要优势。     

Formation of particle jetting in a cylindrical shock tube

A dense, solid particle flow is numerically studied at a mesoscale level for a cylindrical shock tube problem. The shock tube consists of a central high pressure gas driver section and an annular solid powder bed with air in void regions as a driven section with its far end adjacent to ambient air. Simulations are conducted to explore the fundamental phenomena, causing clustering of particles and formation of coherent particle jet structures in such a dense solid flow. The influence of a range of parameters is investigated, including driver pressure, particle morphology, particle distribution and powder bed configuration. The results indicate that the physical mechanism responsible for this phenomenon is twofold: the driver gas jet flow induced by the shock wave as it passes through the initial gaps between the particles in the innermost layer of the powder bed, and the chaining of solid particles by inelastic collision. The particle jet forming time is determined as the time when the motion of the outermost particle layer of the powder bed is first detected. The maximum number of particle jets is bounded by the total number of particles in the innermost layer of the powder bed. The number of particle jets is mainly a function of the number of particles in the innermost layer and the mass ratio of the powder bed to the gas in the driver section, or the ratio of powder bed mass (in dimensionless form) to the pressure ratio between the driver and driven sections.     

Two-phase discharge from a stratified region through two horizontal branches with centerlines falling on an inclined plane

The main objective of this study was to obtain new experimental data for conditions not previously tested for discharging two-phase flow through two 6.35 mm diameter branches with centerlines falling in an inclined plane. The present results are relevant to many industrial applications including headers and manifolds, multichannel heat exchangers and small breaks in horizontal pipes. In the experimental investigation, the critical heights for the onsets of liquid and gas entrainment (OLE and OGE, respectively) were obtained, analyzed and correlated for two different branch spacings and two different angles between the branches. For each combination of branch spacing and angle between the branches, a wide range of Froude numbers was used. Two-phase mass flow rate and quality results were also obtained and analyzed for a range of interface heights for 16 different combinations of branch spacing, inclination angle, test section pressure and pressure drop across each branch. New empirical correlations were developed to predict the dimensionless mass flow rate and quality. The new correlations show good agreement with the present data and with previous correlations.     

煤仓内煤散料流动状态与力学行为影响因素

针对煤仓内煤散料流动问题及其力学行为,采用三维颗粒流模拟程序PFC3D建立了某型号煤仓与某种煤散料的离散元模型,简述了其力学模型与求解步骤,模拟分析了煤仓内煤散料卸料流动状态。通过分析水平向侧压力、颗粒速度场和接触力场,重点讨论了煤仓下部锥体内壁面摩擦系数、锥仓倾角和卸料口径等对煤散料颗粒流动状态和力学行为的影响。结果显示,深仓卸料流动为整体流动与中心流动混合状态,煤仓内壁摩擦系数、锥体倾角和卸料孔开口半径均对煤散料流动和水平侧压力有较大影响。     

Experimental investigation of flow and heat transfer in rectangular cross-sectioned duct with baffles mounted on the bottom surface with different inclination angles

In this study, steady-state forced convection heat transfer and pressure drop characteristics in a horizontal rectangular cross-sectioned duct, baffles mounted on the bottom surface with different inclination angles were investigated experimentally in the Reynolds number range from 1 × 10³ to 1 × 10⁴. The study was performed under turbulent flow conditions. Effects of different baffle inclination angles on flow and heat transfer were studied. Results are also presented in terms of thermal enhancement factor. It is observed that increasing in baffle inclination angle enhances the heat transfer and causes an increase in pressure drop in the duct.     

倾斜非均匀磁场下导电方管磁流体管流的数值模拟研究

热核聚变反应堆液态金属包层应用中的一个重要问题是液态金属在导电管中流动和强磁场相互作用产生的额外的磁流体动力学压降.这种磁流体动力学压降远远大于普通水力学压降.美国阿贡国家实验室ALEX研究小组,对非均匀磁场下导电管中液态金属磁流体动力学效应进行了实验研究,其实验结果成为液态金属包层数值验证的标准模型之一.液态金属包层在应用中会受到不同方向的磁场作用,本文以ALEX的非均匀磁场下导电方管中液态金属管流实验中的一组参数为基础,保持哈特曼数、雷诺数和壁面电导率不变,采用三维直接数值模拟的方法,研究了外加磁场与侧壁之间的倾角对导电方管内液态金属流动的速度、电流和压降分布的影响.研究结果表明:沿流向相同横截面上的速度、电流以及压力分布均随磁场的倾斜而同向旋转.倾斜磁场均匀段,横截面上的高速区位于平行磁场方向的哈特曼层和平行层交叉位置,压力梯度随磁场倾角的增大先增大后减小.倾斜磁场递减段,在三维磁流体动力学效应作用下,横截面上的高速射流位置向垂直磁场方向偏移.磁场递减段的三维磁流体动力学压降随磁场倾角的增大而增大.随磁场倾斜,截面上的射流峰值逐渐减小,二次流增强,引发层流向湍流的转捩.