CFD Modeling and Simulation in Materials Processing 2018 (eBook)

Laurentiu Nastac, Koulis Pericleous, Adrian S. Sabau, Lifeng Zhang, Brian G. Thomas (Herausgeber)

eBook Download: PDF

2018 | 1st ed. 2018
XIV, 241 Seiten
Springer International Publishing (Verlag)
978-3-319-72059-3 (ISBN)

Infos

This collection presents contributions on computational fluid dynamics (CFD) modeling and simulation of engineering processes from researchers and engineers involved in the modeling of multiscale and multiphase phenomena in material processing systems. 

 

The following processes are covered: Additive Manufacturing (Selective Laser Melting and Laser Powder Bed Fusion); Ironmaking and Steelmaking (Ladle Metallurgical Furnace, EAF, Continuous Casting, Blown Converter, Reheating Furnace, Rotary Hearth Furnace); Degassing; High Pressure Gas Atomization of Liquid Metals; Electroslag Remelting; Electrokinetic Deposition; Friction Stir Welding; Quenching; High Pressure Die Casting; Core Injection Molding; Evaporation of Metals; Investment Casting; Electromagnetic Levitation; Ingot Casting; Casting and Solidification with External Field (electromagnetic stirring and ultrasonic cavitation) Interaction and Microstructure Evolution

 

The collection also covers applications of CFD to engineering processes, and demonstrates how CFD can help scientists and engineers to better understand the fundamentals of engineering processes.

The Minerals, Metals & Materials Society (TMS) is a member-driven international professional society dedicated to fostering the exchange of learning and ideas across the entire range of materials science and engineering, from minerals processing and primary metals production, to basic research and the advanced applications of materials. Included among its nearly 13,000 professional and student members are metallurgical and materials engineers, scientists, researchers, educators, and administrators from more than 70 countries on six continents. 

Inhalt

Preface 5
Contents 6
About the Editors 9
Casting and Solidification: I 13
1 Numerical Simulation on Solidification Structure of 30Cr2Ni4MoV Steel Under Different Temperature Gradient Using Procast Software 14
Abstract 14
Experimental 16
Numerical Simulation Results 17
Conclusions 18
References 19
2 Influence of Coil Configuration on Flow Characteristics in Electromagnetic Solidification Systems 20
Abstract 20
Introduction 20
Model Formulation 21
Heat Transfer 22
Fluid Flow 22
Results and Discussion 23
Conclusions 27
References 28
3 Effect of Hook Formation During Initial Solidification on Distribution of Subsurface Inclusions in Ultralow Carbon Steel Slabs 30
Abstract 30
Introduction 30
Methodology 31
Inclusion Statistics 31
Water Simulations and PIV Measurements 31
Results and Discussion 33
Inclusion Content in Different Surface Layers 33
Inclusion Movements in Hook Region 34
Characteristics of Molten Steel Flow in Hook Region 36
Conclusions 37
References 38
Casting and Solidification: II 39
4 Numerical Investigation on the Effect of Steel Strip Feeding on Solidification in Continuous Casting 40
Abstract 40
Introduction 40
Mathematical Model 41
General Equations of the Model 42
Boundary Conditions 43
Computational Procedure 44
Results and Discussion 46
Validation 46
Evolution of Strip Melting 46
Strip Thickness Evolution 46
Strip Travels Distance 47
Effect of Strip Feeding on Fluid Flow 48
Effect of Strip Feeding on Liquid Steel Superheat 49
Conclusions 50
Acknowledgements 51
References 51
5 Numerical Modeling and Experimental Verification of Macrosegregation and CET Predictions in Large Steel Roll Ingots 52
Abstract 52
Introduction 52
Model Description 53
Simulation Conditions 54
Results and Discussion 54
Conclusions 60
References 60
6 Numerical Simulation of Electromagnetic and Heat Transfer Phenomena in Inductively Heated Risers 61
Abstract 61
Introduction 61
Model Formulation 63
Electromagnetic Field 63
Heat Transfer 64
Results and Discussion 64
Conclusions 69
References 69
Processing: I 71
7 A Multiphase CFD Model for the Prediction of Particulate Accumulation in a Laser Powder Bed Fusion Process 72
Abstract 72
Introduction 73
By-Products and Shielding Gas Flow 73
Experimental Gas Flow Testing 76
Shielding Gas Flow Model 77
Boundary Conditions and Mesh 77
Validation of Simulation Against Experimental Results 78
Spatter Expulsion Model 79
Metal Vapour Plume Model 80
Analysis and Discussion 81
Conclusions 82
Acknowledgements 82
References 83
8 CFD Modelling of High Pressure Gas Atomization of Liquid Metals 84
Abstract 84
Introduction 84
Computational Methods 86
Experimental Methods 87
Results 88
Summary and Conclusions 90
Acknowledgements 90
References 91
9 Computational Analysis of Thermo-Fluid Dynamics with Metallic Powder in SLM 92
Abstract 92
Introduction 92
Numerical Modeling Approach 94
Powder Scale Model 94
Application of Volumetric Heat Source 95
Material Properties 95
Results and Discussion 96
Single Layer-Single Track Simulation 96
Two Layer-Single Track Simulations 98
Conclusions 101
Acknowledgements 101
References 101
10 Evaporation and Diffusion of Mn in Inert Systems 103
Abstract 103
Introduction 103
Model Development 104
Experiments 108
Results 111
Discussion 111
Conclusions 115
Further Work 115
References 116
Processing: II 117
11 Recent Development and Applications of CFD Simulation for Friction Stir Welding 118
Abstract 118
Introduction 118
General Governing Equations for Simulation of FSW 119
Special Considerations in CFD Simulation of FSW 120
Prediction of Microstructural Features and Defects in Welds 121
Validation of Simulation Data 121
Conclusions and Outlook 122
Acknowledgements 122
References 122
12 Modeling of Argon Gas Behavior in Continuous Casting of Steel 124
Abstract 124
Introduction 125
Model Description 125
Governing Equations of EEDPM 125
Modeling of Shearing off Process 126
Modeling of Bubble Interactions 127
Modeling of Volumetric Expansion 129
Results and Discussion 129
Conclusions 135
Acknowledgements 135
References 136
13 CFD Modeling of Transport Phenomena and Inclusion Removal in a Gas-Stirred Ladle 137
Abstract 137
Introduction 137
Mathematical Model 138
Results and Discussion 139
Conclusions 142
References 143
14 An Innovative Modeling Approach for Predicting the Desulfurization Kinetics in an Argon-Stirred Ladle Furnace 144
Abstract 144
Introduction 145
Model Description 145
CFD Model 146
Desulfurization Kinetics Modeling Approach 147
Results and Discussion 147
Kinetic Results by CFD Model 147
Desulfurization Predictions 149
Concluding Remarks 150
References 150
15 Simulation of Non-metallic Inclusion Deposition and Clogging of Nozzle 152
Abstract 152
Introduction 153
Model in Brief 154
Results and Discussion 157
Conclusions 160
Acknowledgements 160
References 160
16 Research on the Flow Properties and Erosion Characteristics in Combined Blown Converter at Steelmaking Temperature 162
Abstract 162
Introduction 162
Mathematical Model 163
Geometry Model and Computation Procedure 163
Turbulence and VOF Model 166
Energy Model 167
Assumptions 167
Results and Discussion 167
Effect of Ambient Temperature on Jet Characteristics 167
Effect of Ambient Temperature on Jet-Bath Interactions 169
Effect of Radial Angle Between Multi Nozzles and Multi Tuyeres on Flow Properties 171
Conclusions 173
Acknowledgements 174
References 174
Processing: III 175
17 Effect of Carbide Configuration on the Current Distribution in Submerged Arc Furnaces for Silicon Production—A Modelling Approach 176
Abstract 176
Introduction 177
Computational Model 179
Mathematical Modeling 179
Furnace Geometry and Material Properties 180
Mesh Generation and Boundary Conditions 181
Numerical Cases 181
Conclusions 185
Acknowledgements 185
References 185
18 Investigation of Combustion and Heat Transfer in an Industrial Reheating Furnace Using CFD 187
Abstract 187
Introduction 187
Numerical Models 188
The Species Conservation Equation 189
Combustion Model (Eddy Dissipation Concept) 189
The Discrete Ordinates (DO) Radiation Model 190
The Weighted-Sum-of-Gray-Gases Model (WSGGM) 190
Simulation Conditions 191
Simulation Domain and Mesh 191
Boundary Conditions 192
Model Validation 193
Results and Discussion 195
Furnace Gas Temperature 195
Parameter Study in Bottom Intermediate Zone 195
Conclusions 197
Acknowledgements 198
References 198
19 Finite Element Modelling of Electrokinetic Deposition of Zinc on Mild Steel with ZnO-Citrus sinensis as Nano-Additive 199
Abstract 199
Introduction 200
Materials and Methods 201
Pre-processing 201
Processing and Analysis 203
Post-processing 206
Results and Discussion 206
Electrolyte Potential 206
Anode Electrode Change 206
Cathode Electrode Change 207
Comparison of the Results of Cathode Change from the FE Solver with Experimentation 208
Effect of ZnO-Citrus sinensis Nano-Additive on the Electrokinetic Deposition 209
Conclusion 210
References 210
20 Implementing CFD Modelling to Address Defect Formation in Core Injection Moulding 212
Abstract 212
Introduction 212
Materials and Methods 213
Results and Discussion 215
Filling Pattern 215
Shear Rates 217
Solidification 218
Conclusions 219
Acknowledgements 220
References 220
21 Numerical Simulation of Turbulence Flow and Solidification in a Bloom Continuous Casting Mould with Electromagnetic Stirring 222
Abstract 222
Introduction 222
Mathematical Model 223
Assumptions 224
Governing Equations 224
Boundary Conditions 225
Numerical Solution Procedure 226
Results and Discussion 227
Electromagnetic Field 227
Flow Field and Solidification 229
Conclusion 234
References 234
Author Index 236
Subject Index 238

Produkt-Details

• Erscheint lt. Verlag: 10.1.2018
• Reihe/Serie: The Minerals, Metals & Materials Series
• Reihe/Serie: The Minerals, Metals & Materials Series
• Zusatzinfo: XIV, 241 p. 144 illus.
• Verlagsort: Cham
• Sprache: englisch
• Themenwelt: Technik ► Maschinenbau
• Schlagworte: Additive Manufacturing • Data-driven Science, Modeling and Theory Building • Electromagnetic Stirring and Ultrasonic Cavitation Processing • Ironmaking and Steelmaking • Remelting Processes • solidification • Welding, Casting, and Heat Treatment Processes
• ISBN-10: 3-319-72059-7 / 3319720597
• ISBN-13: 978-3-319-72059-3 / 9783319720593