Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing addit...Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing additive-induced defects,and alleviating residual stress and deformation,all of which are critical for enhancing the mechanical performance of the manufactured parts.Integrating interlayer friction stir processing(FSP)into WAAM significantly enhances the quality of deposited materials.However,numerical simulation research focusing on elucidating the associated thermomechanical coupling mechanisms remains insufficient.A comprehensive numerical model was developed to simulate the thermomechanical coupling behavior in friction stir-assisted WAAM.The influence of post-deposition FSP on the coupled thermomechanical response of the WAAM process was analyzed quantitatively.Moreover,the residual stress distribution and deformation behavior under both single-layer and multilayer deposition conditions were investigated.Thermal analysis of different deposition layers in WAAM and friction stir-assisted WAAM was conducted.Results show that subsequent layer deposition induces partial remelting of the previously solidified layer,whereas FSP does not cause such remelting.Furthermore,thermal stress and deformation analysis confirm that interlayer FSP effectively mitigates residual stresses and distortion in WAAM components,thereby improving their structural integrity and mechanical properties.展开更多
A new three-dimensional multiphase numerical model was built.The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process.During the pouring process,issues such as iron s...A new three-dimensional multiphase numerical model was built.The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process.During the pouring process,issues such as iron splashing,overflow,and significant heat loss are prevalent.To realize efficient and stable pouring,the effects of ladle tilting velocity,flow rate,and converter tilting angle on the pouring process were examined.The model was verified by comparing the actual pouring time with the numerical results.It is shown that there is a nonlinear relationship between pouring velocity and hot metal flow rate at the ladle mouth.As the mass flow increased and the converter tilting angle decreased,the impact point of the hot metal into the converter pool shifted from the side wall to the bottom,and the impact force increased accordingly.The pouring velocity curve was optimized by the volume difference of the ladle at different angles,and an empirical formula was derived.After the optimization of pouring speed,the flow rate was stabilized between 4000 and 6000 kg/s,and the pouring time was reduced by approximately 30 s.After applying this model in actual production,the hot metal temperature inside the converter increased by approximately 5℃statistically.This model is potential to enhance the production efficiency,stability,and safety of the pouring process between open containers.展开更多
In the electroslag remelting(ESR)process,it mainly relies on thermal experiments or analysis via mechanistic models to realize the physical fields simulation of the electromagnetic field and temperature field coupled ...In the electroslag remelting(ESR)process,it mainly relies on thermal experiments or analysis via mechanistic models to realize the physical fields simulation of the electromagnetic field and temperature field coupled transfer,which has the limitations of high cost,a large amount of calculating data and high computing power requirements.A novel network based on physics-informed neural network(PINN)was designed to realize the fast and high-fidelity prediction of the distribution of electromagnetic field and temperature field in ESR process.The physical laws were combined with the deep learning network through PINN,and physical constraints were embedded to achieve effective solution of partial differential equations(PDEs).PINN was used to minimize the loss function consisting of data error,physical information error and boundary condition error.The physical laws and boundary condition constraints in the ESR process were considered to maintain high PDE solution accuracy under different spatial and temporal resolutions.Automatic differentiation(Autodiff)technique and gradient descent algorithm were used to optimize the network parameters.The experimental results show that compared with the mechanistic models,PINN can effectively replace thermal experiments to realize the physical field simulation of ESR process with only a few experimental data,which can avoid the disadvantages of pure data-driven network simulation that requires a large amount of training data.Moreover,the solution of PINN has good physical interpretability and reliability of simulation results.For simulating electromagnetic field and temperature field distribution,the training time of the network is only 140 and 203 s,and the regression indicators of root mean square error can reach 12.65 and 13.76,respectively.展开更多
Sequential-modular-based process flowsheeting software remains an indispensable tool for process design,control,and optimization.Yet,as the process industry advances in intelligent operation and maintenance,convention...Sequential-modular-based process flowsheeting software remains an indispensable tool for process design,control,and optimization.Yet,as the process industry advances in intelligent operation and maintenance,conventional sequential-modular-based process-simulation techniques present challenges regarding computationally intensive calculations and significant central processing unit(CPU)time requirements,particularly in large-scale design and optimization tasks.To address these challenges,this paper proposes a novel process-simulation parallel computing framework(PSPCF).This framework achieves layered parallelism in recycling processes at the unit operation level.Notably,PSPCF introduces a groundbreaking concept of formulating simulation problems as task graphs and utilizes Taskflow,an advanced task graph computing system,for hierarchical parallel scheduling and the execution of unit operation tasks.PSPCF also integrates an advanced work-stealing scheme to automatically balance thread resources with the demanding workload of unit operation tasks.For evaluation,both a simpler parallel column process and a more complex cracked gas separation process were simulated on a flowsheeting platform using PSPCF.The framework demonstrates significant time savings,achieving over 60%reduction in processing time for the simpler process and a 35%–40%speed-up for the more complex separation process.展开更多
In the ultra-deep strata of the Tarim Basin,the vertical growth process of strike-slip faults remains unclear,and the vertical distribution of fractured-cavity carbonate reservoirs is complex.This paper investigates t...In the ultra-deep strata of the Tarim Basin,the vertical growth process of strike-slip faults remains unclear,and the vertical distribution of fractured-cavity carbonate reservoirs is complex.This paper investigates the vertical growth process of strike-slip faults through field outcrop observations in the Keping area,interpretation of seismic data from the Fuman Oilfield,Tarim Basim,NW China,and structural physical simulation experiments.The results are obtained mainly in four aspects.First,field outcrops and ultra-deep seismic profiles indicate a three-layer structure within the strike-slip fault,consisting of fault core,fracture zone and primary rock.The fault core can be classified into three parts vertically:fracture-cavity unit,fault clay and breccia zone.The distribution of fracture-cavity units demonstrates a distinct pattern of vertical stratification,owing to the structural characteristics and growth process of the slip-strike fault.Second,the ultra-deep seismic profiles show multiple fracture-cavity units in the strike-slip fault zone.These units can be classified into four types:top fractured,middle connected,deep terminated,and intra-layer fractured.Third,structural physical simulation experiments and ultra-deep seismic data interpretation reveal that the strike-slip faults have evolved vertically in three stages:segmental rupture,vertical growth,and connection and extension.The particle image velocimetry detection demonstrates that the initial fracture of the fault zone occurred at the top or bottom and then evolved into cavities gradually along with the fault growth,accompanied by the emergence of new fractures in the middle part of the strata,which subsequently connected with the deep and shallow cavities to form a complete fault zone.Fourth,the ultra-deep carbonate strata primarily develop three types of fractured-cavity reservoirs:flower-shaped fracture,large and deep fault and staggered overlap.The first two types are larger in size with better reservoir conditions,suggesting a significant exploration potential.展开更多
To understand the flow trace of semi-solid slurry in mold cavity, some thermocouples were inserted in mold cavity, and the reaction timing of thermocouples showed the arrival of fluid. The filling time and rate were e...To understand the flow trace of semi-solid slurry in mold cavity, some thermocouples were inserted in mold cavity, and the reaction timing of thermocouples showed the arrival of fluid. The filling time and rate were estimated by comparison between the experiment and calculation. The introduction of computer simulation technique based on ADSTEFAN was to predict injectionforming process and to prevent defects during trial manufacture of various parts. By comparing the formed appearance of parts in experiment and in simulation, and observing the relationship between internal defects inspected by X-ray or microscope and the flow field obtained in simulation, it was indicated that both have quite good agreement in simulation and experiment. Right predictions for cast defects resulted from mold rilling can be carried out and proper direction was also proposed. The realization of numerical visualization for filling process during semi-solid die-cast process will play an important role in optimizing technology plan.展开更多
Simulations of photoresist etching,aerial image,exposure,and post-bake processes are integrated to obtain a photolithography process simulation for microelectromechanical system（MEMS） and integrated circuit（IC） fa...Simulations of photoresist etching,aerial image,exposure,and post-bake processes are integrated to obtain a photolithography process simulation for microelectromechanical system（MEMS） and integrated circuit（IC） fabrication based on three-dimensional （3D） cellular automata（CA）. The simulation results agree well with available experimental results. This indicates that the 3D dynamic CA model for the photoresist etching simulation and the 3D CA model for the post-bake simulation could be useful for the monolithic simulation of various lithography processes. This is determined to be useful for the device-sized fabrication process simulation of IC and MEMS.展开更多
The three-dimensional （3D） processing maps considering strain based on the two-dimensional （2D） processing maps proposed by PRASAD can describe the distribution of the efficiency of power dissipation and flow inst...The three-dimensional （3D） processing maps considering strain based on the two-dimensional （2D） processing maps proposed by PRASAD can describe the distribution of the efficiency of power dissipation and flow instability regions at various temperatures, strain rates and strains, which exhibit intrinsic workability related to material itself. Finite element （FE） simulation can obtain the distribution of strain, strain rate, temperature and die filling status, which indicates state-of-stress （SOS） workability decided by die shape and different processing conditions. On the basis of this, a new material driven analysis method for hot deformation was put forward by the combination of FE simulation with 3D processing maps, which can demonstrate material workability of the entire hot deformation process including SOS workability and intrinsic workability. The hot forging process for hard-to-work metal magnesium alloy was studied, and the 3D thermomechanical FE simulation including 3D processing maps of complex hot forging spur bevel gear was first conducted. The hot forging experiments were carried out. The results show that the new method is reasonable and suitable to determine the aoorooriate nrocess narameters.展开更多
The absorbing process in isolating and coating process of α-olefin drag reducing polymer was studied by molecular dynamic simulation method, on basis of coating theory of α-olefin drag reducing polymer particles wit...The absorbing process in isolating and coating process of α-olefin drag reducing polymer was studied by molecular dynamic simulation method, on basis of coating theory of α-olefin drag reducing polymer particles with polyurethane as coating material. The distributions of sodium laurate, sodium dodeeyl sulfate, and sodium dodeeyl benzene sulfonate on the surface of α-olefin drag reducing polymer particles were almost the same, but the bending degrees of them were obviously different. The bending degree of SLA molecules was greater than those of the other two surfactant molecules. Simulation results of absorbing and accumulating structure showed that, though hydrophobie properties of surfactant molecules were almost the same, water density around long chain sulfonate sodium was bigger than that around alkyl sulfate sodium. This property goes against useful absorbing and accumulating on the surface of α-olefin drag reducing polymer particles; simulation results of interactions of different surfactant and multiple hydroxyl compounds on surface of particles showed that, interactions of different surfaetant and one kind of multiple hydroxyl compound were similar to those of one kind of surfaetant and different multiple hydroxyl compounds. These two contrast types of interactions also exhibited the differences of absorbing distribution and closing degrees to surface of particles. The sequence of closing degrees was derived from simulation; control step of addition polymerization interaction in coating process was absorbing mass transfer process, so the more closed to surface of particle the multiple hydroxyl compounds were, the easier interactions With isoeyanate were. Simulation results represented the compatibility relationship between surfactant and multiple hydroxyl compounds. The isolating and coating processes of α-olefin drag reducing polymer were further understood on molecule and atom level through above simulation research, and based on the simulation, a referenced theoretical basis was provided for practical optimal selection and experimental preparation of α-olefin drag reducing polymer particles suspension isolation agent.展开更多
The vacuum die-casting process,started 25 years ago in Japan,has been widely applied.This technology contributes very much to improvement of castings quality.The main factor causing the defects of die castings is the ...The vacuum die-casting process,started 25 years ago in Japan,has been widely applied.This technology contributes very much to improvement of castings quality.The main factor causing the defects of die castings is the trapped air in the mold cavity,while the key technology of vacuum die-casting process is to avoid the trapped air effectively by evacuating the cavity before casting.At the same time,due to the shot speed and the casting pressure reduced in half,the service life of the die is prolonged and the productivity is enhanced,as well.Vacuum die-casting process is of great signif icance in improving the die castings quality and making up the shortcomings of super-high-speed shot casting.展开更多
The aim of this study was to simulate the solidification process of beam blank continuous casting, and then find the reasons for the typical defects of the beam blank. A two-dimensional transient coupled finite elemen...The aim of this study was to simulate the solidification process of beam blank continuous casting, and then find the reasons for the typical defects of the beam blank. A two-dimensional transient coupled finite element model has been developed to compute the temperature and stress profile in beam blank continuous casting. The enthalpy method was used in the heat conduction equation. The thermo-mechanical property in the mushy zone was taken into consideration in this calculation. It is shown that at the mold exit the thickness of the shell had its maximum value at the flange tip and its minimum value at the fillet. The temperature had a great fluctuation on the surface of the beam blank in the secondary cooling zone. At the unbending point, the surface temperature of the web was in the brittleness temperature range under the present condition. To ensure the quality, it is necessary to weaken the intensity of secondary cooling. At the mold exit the equivalent stress and strain have higher values at the flange tip and at the web. From the spray 1 to the unbending point, the maximum values of stress and strain gradually moved to the internal section of the flange tip and the web. However, whenever, there were bigger stress and strain values near the flange tip and the web than in the other parts, it must be very easy to generate cracks at those positions. Now, online verification of this simulation has been developed, which has proved to be very useful and efficient to instruct the practical production of beam blank continuous casting.展开更多
A molecular dynamics simulation study has been performed for the microstructure evolution in a liquid metal Ni system during crystallization process at two cooling rates by adopting the embedded atom method （EAM） mo...A molecular dynamics simulation study has been performed for the microstructure evolution in a liquid metal Ni system during crystallization process at two cooling rates by adopting the embedded atom method （EAM） model potential. The bond-type index method of Honeycutt-Andersen （HA） and a new cluster-type index method （CTIM-2） have been used to detect and analyse the microstructures in this system. It is demonstrated that the cooling rate plays a critical role in the microstructure evolution： below the crystallization temperature Tc, the effects of cooling rate are very remarkable and can be fully displayed. At different cooling rates of 2.0 × 10^13 K·s^-1 and 1.0 × 10^12 K·s^-1, two different kinds of crystal structures are obtained in the system. The first one is the coexistence of the hcp （expressed by （12 0 0 0 6 6） in CTIM-2） and the fcc （12 0 0 0 12 0） basic clusters consisting of 1421 and 1422 bond-types, and the hcp basic cluster becomes the dominant one with decreasing temperature, the second one is mainly the fcc （12 0 0 0 12 0） basic clusters consisting of 1421 bond-type, and their crystallization temperatures Tc would be 1073 and 1173 K, respectively.展开更多
The western coast of Hainan Island exhibits a savanna landscape. Many types of sand dunes, including transverse dune ridges, longitudinal dune ridges, elliptical dunes, coppice dunes, and climbing dunes, are widely di...The western coast of Hainan Island exhibits a savanna landscape. Many types of sand dunes, including transverse dune ridges, longitudinal dune ridges, elliptical dunes, coppice dunes, and climbing dunes, are widely distributed in the coastal zone. In winter, high-frequency and high-energy NE winds （dominant winds） are prevalent, with a resultant drift direction （RDD） of S35.6°W. In spring, low-frequency and low-energy SW secondary winds prevail, with a RDD of N25.1°E. Wind tunnel simulations revealed that the airflow over the dune surface is the main factor controlling the erosion and deposition patterns of dune surfaces and the morphological development of dunes. In the region＇s bidirectional wind environment, with two seasonally distinct energy levels, the airflow over the surface of elliptical dunes, barchan dunes, and transverse dune ridges will exhibit a transverse pattern, whereas the airflow over longitudinal dunes ridges exhibits a lateral pattern and that over climbing dunes exhibits a climbing-circumfluent pattern. These patterns represent different dynamic processes. The coastal dunes on the western coast of Hainan Island are influenced by factors such as onshore winds, sand sources, coastal slopes, rivers, and forest shelter belts. The source of the sand that supplements these dunes particularly influences the development pattern： when there is more sand, the pattern shows positive equilibrium deposition between dune ridges and dunes; otherwise, it shows negative equilibrium deposition. The presence or absence of forest shelter belts also influences deposition and dune development patterns and transformation of dune forms. Coastal dunes and inland desert dunes experience similar dynamic processes, but the former have more diversified shapes and more complex formation mechanisms.展开更多
Turbidity currents represent a major agent for sediment transport in lakes, seas and oceans. In particu-lar, they formulate the most significant clastic accumulations in the deep sea, which become many of the world＇s...Turbidity currents represent a major agent for sediment transport in lakes, seas and oceans. In particu-lar, they formulate the most significant clastic accumulations in the deep sea, which become many of the world＇s most important hydrocarbon reservoirs. Several boreholes in the Qiongdongnan Basin, the north-western South China Sea, have recently revealed turbidity current deposits as significant hydrocarbon res-ervoirs. However, there are some arguments for the potential provenances. To solve this problem, it is es-sential to delineate their sedimentary processes as well as to evaluate their qualities as reservoir. Numerical simulations have been developed rapidly over the last several years, offering insights into turbidity current behaviors, as geologically significant turbidity currents are difficult to directly investigate due to their large scale and often destructive nature. Combined with the interpretation of the turbidity system based on high-resolution 3D seismic data, the paleotophography is acquired via a back-stripping seismic profile integrated with a borehole, i.e., Well A, in the western Qiongdongnan Basin; then a numerical model is built on the basis of this back-stripped profile. After defining the various turbidity current initial boundary conditions, includ-ing grain size, velocity and sediment concentration, the structures and behaviors of turbidity currents are investigated via numerical simulation software ANSYS FLUENT. Finally, the simulated turbidity deposits are compared with the interpreted sedimentary bodies based on 3D seismic data and the potential provenances of the revealed turbidites by Well A are discussed in details. The simulation results indicate that a sedimen-tary body develops far away from its source with an average grain size of 0.1 mm, i.e., sand-size sediment. Taking into account the location and orientation of the simulated seismic line, the consistence between normal forward simulation results and the revealed cores in Well A indicates that the turbidites should have been transported from Vietnam instead of Hainan Island. This interpretation has also been verified by the planar maps of sedimentary systems based on integration of boreholes and seismic data. The identification of the turbidity provenance will benefit the evaluation of extensively distributed submarine fans for hydro-carbon exploration in the deepwater areas.展开更多
A new 18-lump kinetic model for naphtha catalytic reforming reactions is discussed. By developing this model as a user module, a whole industrial continuous catalytic reforming process is simulated on Aspen plus plat-...A new 18-lump kinetic model for naphtha catalytic reforming reactions is discussed. By developing this model as a user module, a whole industrial continuous catalytic reforming process is simulated on Aspen plus plat-form. The technique utilizes the strong databases, complete sets of modules, and flexible simulation tools of the Aspen plus system and retains the characteristics of the proposed kinetic model. The calculated results are in fair agreement with the actual operating data. Based on the model of the whole reforming process, the process is opti-mized and the optimization results are tested in the actual industrial unit for about two months. The test shows that the process profit increases about 1000yuan·h-1 averagely, which is close to the calculated result.展开更多
The finite element method(FEM)is used for simulation of the tube piercing process in Mannesmann mill.The numerical model is described with taking into consideration thermal phenomena in metal during forming. The simul...The finite element method(FEM)is used for simulation of the tube piercing process in Mannesmann mill.The numerical model is described with taking into consideration thermal phenomena in metal during forming. The simulated results visualize dynamic distributions of mean stresses,temperature,velocity and shear stresses, especially inside the workpiece.On the basis of the basic parameters,the phenomenon in the piercing process is analyzed.The model is verified by comparing the values of calculated force parameters of the piercing process and those measured in laboratory conditions.展开更多
Numerical simulation of casting＇s mold filling process is the main and the most important aspect of the foundry CAE technology. But it is time-consuming; it may take dozens of hours or several days. While with the de...Numerical simulation of casting＇s mold filling process is the main and the most important aspect of the foundry CAE technology. But it is time-consuming; it may take dozens of hours or several days. While with the development of computer hardware, numerical simulation of casting＇ s mold filling process has made rapid progress. The simulation results, therefore, have become more and more practical. This study tries to find some clues of the computational time of mold filling process. Firstly, this paper introduces mathematic model and the basic route of numerical simulation of casting＇s mold filling process. Then the computational time of mold filling process has been carefully studied, and some new and useful results have been gained from the study of the computational time. Finally, this paper has given some real applications of numerical simulation of casting＇s mold filling process.展开更多
A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow...A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.展开更多
Based on test data from the hot forge experiments on Gleeble 1500, a Kumar type constitutive equation for 33Mn2V steel is established. Applying this constitutive equation in commercial FEM software of MSC/SuperForm 20...Based on test data from the hot forge experiments on Gleeble 1500, a Kumar type constitutive equation for 33Mn2V steel is established. Applying this constitutive equation in commercial FEM software of MSC/SuperForm 2005, the piercing process of 33Mn2V steel in Mannesmann mill is then simulated. The modeling results visualized the dynamic evolution of equivalent stress, especially inside the workpieee. It is shown that the non-uniform distribu- tion of stress on the internal and external surface of the workpiece is a distinct characteristic of processing tube pierc- ing. The numerical model was verified by comparing the values of calculated force parameters of the piercing process with those measured in laboratory eonditions. And it shows that the Kumar-type constitutive relationship meets the practical needs.展开更多
The numerical simulation technique was applied to the casting process of a valve-type part. The mold-filling and solidification stages of the casting were numerically analyzed. The filling behavior, solidification seq...The numerical simulation technique was applied to the casting process of a valve-type part. The mold-filling and solidification stages of the casting were numerically analyzed. The filling behavior, solidification sequence, and thermal stress distribution were reproduced and the possible defects, such as cold shut and shrinkage, were predicted. Based on the simulation result, the double-gating system was replaced by a single-gating system. Meanwhile, the chills were used to regulate the solidification sequence of casting. To eliminate the cracks in the casting, the sand core was converted into a canulate one. By modifying the original process, the defects were eliminated and the casting with good quality was obtained.展开更多
基金National Key Research and Development Program of China(2022YFB4600902)Shandong Provincial Science Foundation for Outstanding Young Scholars(ZR2024YQ020)。
文摘Wire arc additive manufacturing(WAAM)has emerged as a promising approach for fabricating large-scale components.However,conventional WAAM still faces challenges in optimizing microstructural evolution,minimizing additive-induced defects,and alleviating residual stress and deformation,all of which are critical for enhancing the mechanical performance of the manufactured parts.Integrating interlayer friction stir processing(FSP)into WAAM significantly enhances the quality of deposited materials.However,numerical simulation research focusing on elucidating the associated thermomechanical coupling mechanisms remains insufficient.A comprehensive numerical model was developed to simulate the thermomechanical coupling behavior in friction stir-assisted WAAM.The influence of post-deposition FSP on the coupled thermomechanical response of the WAAM process was analyzed quantitatively.Moreover,the residual stress distribution and deformation behavior under both single-layer and multilayer deposition conditions were investigated.Thermal analysis of different deposition layers in WAAM and friction stir-assisted WAAM was conducted.Results show that subsequent layer deposition induces partial remelting of the previously solidified layer,whereas FSP does not cause such remelting.Furthermore,thermal stress and deformation analysis confirm that interlayer FSP effectively mitigates residual stresses and distortion in WAAM components,thereby improving their structural integrity and mechanical properties.
基金supported by the National Natural Science Foundation of China(Grant Nos.52104318 and 52374322).
文摘A new three-dimensional multiphase numerical model was built.The volume of fluid and k-ε turbulence models were used to investigate the hot metal ladle pouring process.During the pouring process,issues such as iron splashing,overflow,and significant heat loss are prevalent.To realize efficient and stable pouring,the effects of ladle tilting velocity,flow rate,and converter tilting angle on the pouring process were examined.The model was verified by comparing the actual pouring time with the numerical results.It is shown that there is a nonlinear relationship between pouring velocity and hot metal flow rate at the ladle mouth.As the mass flow increased and the converter tilting angle decreased,the impact point of the hot metal into the converter pool shifted from the side wall to the bottom,and the impact force increased accordingly.The pouring velocity curve was optimized by the volume difference of the ladle at different angles,and an empirical formula was derived.After the optimization of pouring speed,the flow rate was stabilized between 4000 and 6000 kg/s,and the pouring time was reduced by approximately 30 s.After applying this model in actual production,the hot metal temperature inside the converter increased by approximately 5℃statistically.This model is potential to enhance the production efficiency,stability,and safety of the pouring process between open containers.
基金supported by National Natural Science Foundation of China(52274323 and 524743495)the Postdoctoral Fellowship Program of CPSF under Grant Number GZC20240231.
文摘In the electroslag remelting(ESR)process,it mainly relies on thermal experiments or analysis via mechanistic models to realize the physical fields simulation of the electromagnetic field and temperature field coupled transfer,which has the limitations of high cost,a large amount of calculating data and high computing power requirements.A novel network based on physics-informed neural network(PINN)was designed to realize the fast and high-fidelity prediction of the distribution of electromagnetic field and temperature field in ESR process.The physical laws were combined with the deep learning network through PINN,and physical constraints were embedded to achieve effective solution of partial differential equations(PDEs).PINN was used to minimize the loss function consisting of data error,physical information error and boundary condition error.The physical laws and boundary condition constraints in the ESR process were considered to maintain high PDE solution accuracy under different spatial and temporal resolutions.Automatic differentiation(Autodiff)technique and gradient descent algorithm were used to optimize the network parameters.The experimental results show that compared with the mechanistic models,PINN can effectively replace thermal experiments to realize the physical field simulation of ESR process with only a few experimental data,which can avoid the disadvantages of pure data-driven network simulation that requires a large amount of training data.Moreover,the solution of PINN has good physical interpretability and reliability of simulation results.For simulating electromagnetic field and temperature field distribution,the training time of the network is only 140 and 203 s,and the regression indicators of root mean square error can reach 12.65 and 13.76,respectively.
基金supported by the National Key Research and Development Program of China(2022YFB3305900)the National Natural Science Foundation of China(Key Program)(62136003)+2 种基金the National Natural Science Foundation of China(62394345)the Major Science and Technology Projects of Longmen Laboratory(LMZDXM202206)the Fundamental Research Funds for the Central Universities.
文摘Sequential-modular-based process flowsheeting software remains an indispensable tool for process design,control,and optimization.Yet,as the process industry advances in intelligent operation and maintenance,conventional sequential-modular-based process-simulation techniques present challenges regarding computationally intensive calculations and significant central processing unit(CPU)time requirements,particularly in large-scale design and optimization tasks.To address these challenges,this paper proposes a novel process-simulation parallel computing framework(PSPCF).This framework achieves layered parallelism in recycling processes at the unit operation level.Notably,PSPCF introduces a groundbreaking concept of formulating simulation problems as task graphs and utilizes Taskflow,an advanced task graph computing system,for hierarchical parallel scheduling and the execution of unit operation tasks.PSPCF also integrates an advanced work-stealing scheme to automatically balance thread resources with the demanding workload of unit operation tasks.For evaluation,both a simpler parallel column process and a more complex cracked gas separation process were simulated on a flowsheeting platform using PSPCF.The framework demonstrates significant time savings,achieving over 60%reduction in processing time for the simpler process and a 35%–40%speed-up for the more complex separation process.
基金Supported by the National Natural Science Foundation of China(42362026)Key R&D Project of Xinjiang Uygur Autonomous Region(2024B01015).
文摘In the ultra-deep strata of the Tarim Basin,the vertical growth process of strike-slip faults remains unclear,and the vertical distribution of fractured-cavity carbonate reservoirs is complex.This paper investigates the vertical growth process of strike-slip faults through field outcrop observations in the Keping area,interpretation of seismic data from the Fuman Oilfield,Tarim Basim,NW China,and structural physical simulation experiments.The results are obtained mainly in four aspects.First,field outcrops and ultra-deep seismic profiles indicate a three-layer structure within the strike-slip fault,consisting of fault core,fracture zone and primary rock.The fault core can be classified into three parts vertically:fracture-cavity unit,fault clay and breccia zone.The distribution of fracture-cavity units demonstrates a distinct pattern of vertical stratification,owing to the structural characteristics and growth process of the slip-strike fault.Second,the ultra-deep seismic profiles show multiple fracture-cavity units in the strike-slip fault zone.These units can be classified into four types:top fractured,middle connected,deep terminated,and intra-layer fractured.Third,structural physical simulation experiments and ultra-deep seismic data interpretation reveal that the strike-slip faults have evolved vertically in three stages:segmental rupture,vertical growth,and connection and extension.The particle image velocimetry detection demonstrates that the initial fracture of the fault zone occurred at the top or bottom and then evolved into cavities gradually along with the fault growth,accompanied by the emergence of new fractures in the middle part of the strata,which subsequently connected with the deep and shallow cavities to form a complete fault zone.Fourth,the ultra-deep carbonate strata primarily develop three types of fractured-cavity reservoirs:flower-shaped fracture,large and deep fault and staggered overlap.The first two types are larger in size with better reservoir conditions,suggesting a significant exploration potential.
基金Projects(0414) supported by the Science and Technology Development Foundation of Shanghai Automotive Industry
文摘To understand the flow trace of semi-solid slurry in mold cavity, some thermocouples were inserted in mold cavity, and the reaction timing of thermocouples showed the arrival of fluid. The filling time and rate were estimated by comparison between the experiment and calculation. The introduction of computer simulation technique based on ADSTEFAN was to predict injectionforming process and to prevent defects during trial manufacture of various parts. By comparing the formed appearance of parts in experiment and in simulation, and observing the relationship between internal defects inspected by X-ray or microscope and the flow field obtained in simulation, it was indicated that both have quite good agreement in simulation and experiment. Right predictions for cast defects resulted from mold rilling can be carried out and proper direction was also proposed. The realization of numerical visualization for filling process during semi-solid die-cast process will play an important role in optimizing technology plan.
文摘Simulations of photoresist etching,aerial image,exposure,and post-bake processes are integrated to obtain a photolithography process simulation for microelectromechanical system（MEMS） and integrated circuit（IC） fabrication based on three-dimensional （3D） cellular automata（CA）. The simulation results agree well with available experimental results. This indicates that the 3D dynamic CA model for the photoresist etching simulation and the 3D CA model for the post-bake simulation could be useful for the monolithic simulation of various lithography processes. This is determined to be useful for the device-sized fabrication process simulation of IC and MEMS.
基金Project(2011ZX04014-051)supported by the Key Scientific and Technical Project of ChinaProjects(51375306,50905110)supported by the National Natural Science Foundation of China
文摘The three-dimensional （3D） processing maps considering strain based on the two-dimensional （2D） processing maps proposed by PRASAD can describe the distribution of the efficiency of power dissipation and flow instability regions at various temperatures, strain rates and strains, which exhibit intrinsic workability related to material itself. Finite element （FE） simulation can obtain the distribution of strain, strain rate, temperature and die filling status, which indicates state-of-stress （SOS） workability decided by die shape and different processing conditions. On the basis of this, a new material driven analysis method for hot deformation was put forward by the combination of FE simulation with 3D processing maps, which can demonstrate material workability of the entire hot deformation process including SOS workability and intrinsic workability. The hot forging process for hard-to-work metal magnesium alloy was studied, and the 3D thermomechanical FE simulation including 3D processing maps of complex hot forging spur bevel gear was first conducted. The hot forging experiments were carried out. The results show that the new method is reasonable and suitable to determine the aoorooriate nrocess narameters.
文摘The absorbing process in isolating and coating process of α-olefin drag reducing polymer was studied by molecular dynamic simulation method, on basis of coating theory of α-olefin drag reducing polymer particles with polyurethane as coating material. The distributions of sodium laurate, sodium dodeeyl sulfate, and sodium dodeeyl benzene sulfonate on the surface of α-olefin drag reducing polymer particles were almost the same, but the bending degrees of them were obviously different. The bending degree of SLA molecules was greater than those of the other two surfactant molecules. Simulation results of absorbing and accumulating structure showed that, though hydrophobie properties of surfactant molecules were almost the same, water density around long chain sulfonate sodium was bigger than that around alkyl sulfate sodium. This property goes against useful absorbing and accumulating on the surface of α-olefin drag reducing polymer particles; simulation results of interactions of different surfactant and multiple hydroxyl compounds on surface of particles showed that, interactions of different surfaetant and one kind of multiple hydroxyl compound were similar to those of one kind of surfaetant and different multiple hydroxyl compounds. These two contrast types of interactions also exhibited the differences of absorbing distribution and closing degrees to surface of particles. The sequence of closing degrees was derived from simulation; control step of addition polymerization interaction in coating process was absorbing mass transfer process, so the more closed to surface of particle the multiple hydroxyl compounds were, the easier interactions With isoeyanate were. Simulation results represented the compatibility relationship between surfactant and multiple hydroxyl compounds. The isolating and coating processes of α-olefin drag reducing polymer were further understood on molecule and atom level through above simulation research, and based on the simulation, a referenced theoretical basis was provided for practical optimal selection and experimental preparation of α-olefin drag reducing polymer particles suspension isolation agent.
文摘The vacuum die-casting process,started 25 years ago in Japan,has been widely applied.This technology contributes very much to improvement of castings quality.The main factor causing the defects of die castings is the trapped air in the mold cavity,while the key technology of vacuum die-casting process is to avoid the trapped air effectively by evacuating the cavity before casting.At the same time,due to the shot speed and the casting pressure reduced in half,the service life of the die is prolonged and the productivity is enhanced,as well.Vacuum die-casting process is of great signif icance in improving the die castings quality and making up the shortcomings of super-high-speed shot casting.
基金supported by the Hebei Provincial Natural Science Foundation of China(No.E2007000591).
文摘The aim of this study was to simulate the solidification process of beam blank continuous casting, and then find the reasons for the typical defects of the beam blank. A two-dimensional transient coupled finite element model has been developed to compute the temperature and stress profile in beam blank continuous casting. The enthalpy method was used in the heat conduction equation. The thermo-mechanical property in the mushy zone was taken into consideration in this calculation. It is shown that at the mold exit the thickness of the shell had its maximum value at the flange tip and its minimum value at the fillet. The temperature had a great fluctuation on the surface of the beam blank in the secondary cooling zone. At the unbending point, the surface temperature of the web was in the brittleness temperature range under the present condition. To ensure the quality, it is necessary to weaken the intensity of secondary cooling. At the mold exit the equivalent stress and strain have higher values at the flange tip and at the web. From the spray 1 to the unbending point, the maximum values of stress and strain gradually moved to the internal section of the flange tip and the web. However, whenever, there were bigger stress and strain values near the flange tip and the web than in the other parts, it must be very easy to generate cracks at those positions. Now, online verification of this simulation has been developed, which has proved to be very useful and efficient to instruct the practical production of beam blank continuous casting.
基金Project supported by the National Natural Science Foundation of China （Grant Nos 50271026 and 50571037）.
文摘A molecular dynamics simulation study has been performed for the microstructure evolution in a liquid metal Ni system during crystallization process at two cooling rates by adopting the embedded atom method （EAM） model potential. The bond-type index method of Honeycutt-Andersen （HA） and a new cluster-type index method （CTIM-2） have been used to detect and analyse the microstructures in this system. It is demonstrated that the cooling rate plays a critical role in the microstructure evolution： below the crystallization temperature Tc, the effects of cooling rate are very remarkable and can be fully displayed. At different cooling rates of 2.0 × 10^13 K·s^-1 and 1.0 × 10^12 K·s^-1, two different kinds of crystal structures are obtained in the system. The first one is the coexistence of the hcp （expressed by （12 0 0 0 6 6） in CTIM-2） and the fcc （12 0 0 0 12 0） basic clusters consisting of 1421 and 1422 bond-types, and the hcp basic cluster becomes the dominant one with decreasing temperature, the second one is mainly the fcc （12 0 0 0 12 0） basic clusters consisting of 1421 bond-type, and their crystallization temperatures Tc would be 1073 and 1173 K, respectively.
基金National Natural Science Foundation of China, No.40671186 No.40271012
文摘The western coast of Hainan Island exhibits a savanna landscape. Many types of sand dunes, including transverse dune ridges, longitudinal dune ridges, elliptical dunes, coppice dunes, and climbing dunes, are widely distributed in the coastal zone. In winter, high-frequency and high-energy NE winds （dominant winds） are prevalent, with a resultant drift direction （RDD） of S35.6°W. In spring, low-frequency and low-energy SW secondary winds prevail, with a RDD of N25.1°E. Wind tunnel simulations revealed that the airflow over the dune surface is the main factor controlling the erosion and deposition patterns of dune surfaces and the morphological development of dunes. In the region＇s bidirectional wind environment, with two seasonally distinct energy levels, the airflow over the surface of elliptical dunes, barchan dunes, and transverse dune ridges will exhibit a transverse pattern, whereas the airflow over longitudinal dunes ridges exhibits a lateral pattern and that over climbing dunes exhibits a climbing-circumfluent pattern. These patterns represent different dynamic processes. The coastal dunes on the western coast of Hainan Island are influenced by factors such as onshore winds, sand sources, coastal slopes, rivers, and forest shelter belts. The source of the sand that supplements these dunes particularly influences the development pattern： when there is more sand, the pattern shows positive equilibrium deposition between dune ridges and dunes; otherwise, it shows negative equilibrium deposition. The presence or absence of forest shelter belts also influences deposition and dune development patterns and transformation of dune forms. Coastal dunes and inland desert dunes experience similar dynamic processes, but the former have more diversified shapes and more complex formation mechanisms.
基金The National Science and Technology Major Project of China under contract No.2011ZX05025-002-02the National Natural Science Foundation of China under contract Nos 41476032,91028009 and 40806019
文摘Turbidity currents represent a major agent for sediment transport in lakes, seas and oceans. In particu-lar, they formulate the most significant clastic accumulations in the deep sea, which become many of the world＇s most important hydrocarbon reservoirs. Several boreholes in the Qiongdongnan Basin, the north-western South China Sea, have recently revealed turbidity current deposits as significant hydrocarbon res-ervoirs. However, there are some arguments for the potential provenances. To solve this problem, it is es-sential to delineate their sedimentary processes as well as to evaluate their qualities as reservoir. Numerical simulations have been developed rapidly over the last several years, offering insights into turbidity current behaviors, as geologically significant turbidity currents are difficult to directly investigate due to their large scale and often destructive nature. Combined with the interpretation of the turbidity system based on high-resolution 3D seismic data, the paleotophography is acquired via a back-stripping seismic profile integrated with a borehole, i.e., Well A, in the western Qiongdongnan Basin; then a numerical model is built on the basis of this back-stripped profile. After defining the various turbidity current initial boundary conditions, includ-ing grain size, velocity and sediment concentration, the structures and behaviors of turbidity currents are investigated via numerical simulation software ANSYS FLUENT. Finally, the simulated turbidity deposits are compared with the interpreted sedimentary bodies based on 3D seismic data and the potential provenances of the revealed turbidites by Well A are discussed in details. The simulation results indicate that a sedimen-tary body develops far away from its source with an average grain size of 0.1 mm, i.e., sand-size sediment. Taking into account the location and orientation of the simulated seismic line, the consistence between normal forward simulation results and the revealed cores in Well A indicates that the turbidites should have been transported from Vietnam instead of Hainan Island. This interpretation has also been verified by the planar maps of sedimentary systems based on integration of boreholes and seismic data. The identification of the turbidity provenance will benefit the evaluation of extensively distributed submarine fans for hydro-carbon exploration in the deepwater areas.
基金Supported by the National Natural Science Foundation of China (No.60421002).
文摘A new 18-lump kinetic model for naphtha catalytic reforming reactions is discussed. By developing this model as a user module, a whole industrial continuous catalytic reforming process is simulated on Aspen plus plat-form. The technique utilizes the strong databases, complete sets of modules, and flexible simulation tools of the Aspen plus system and retains the characteristics of the proposed kinetic model. The calculated results are in fair agreement with the actual operating data. Based on the model of the whole reforming process, the process is opti-mized and the optimization results are tested in the actual industrial unit for about two months. The test shows that the process profit increases about 1000yuan·h-1 averagely, which is close to the calculated result.
基金the Tianjin Natural Science Foundation (Nos.06YFJMJC02200 and 11JCZDJC22600)Wuxi Steel Tube Factory for its financial support
文摘The finite element method(FEM)is used for simulation of the tube piercing process in Mannesmann mill.The numerical model is described with taking into consideration thermal phenomena in metal during forming. The simulated results visualize dynamic distributions of mean stresses,temperature,velocity and shear stresses, especially inside the workpiece.On the basis of the basic parameters,the phenomenon in the piercing process is analyzed.The model is verified by comparing the values of calculated force parameters of the piercing process and those measured in laboratory conditions.
文摘Numerical simulation of casting＇s mold filling process is the main and the most important aspect of the foundry CAE technology. But it is time-consuming; it may take dozens of hours or several days. While with the development of computer hardware, numerical simulation of casting＇ s mold filling process has made rapid progress. The simulation results, therefore, have become more and more practical. This study tries to find some clues of the computational time of mold filling process. Firstly, this paper introduces mathematic model and the basic route of numerical simulation of casting＇s mold filling process. Then the computational time of mold filling process has been carefully studied, and some new and useful results have been gained from the study of the computational time. Finally, this paper has given some real applications of numerical simulation of casting＇s mold filling process.
文摘A 3-D mathematical model considering turbulence phenomena has been established based on a computational fluid dynamics technique, so called 3-D SOLA-VOF (Solution Algorithm-Volume of Fluid), to simulate the fluid flow of mold filling process of die casting. In addition, the mathematical model for simulating the heat transfer in die casting process has also been established. The computation program has been developed by the authors with the finite difference method (FDM) recently. As verification, the mold filling process of a S-shaped die casting has been simulated and the simulation results coincide with that of the benchmark test. Finally, as a practical application, the gating design of a motorcycle component was modified by the mold filling simulation and the dies design of another motorcycle component was optimized by the heat transfer simulation. All the optimized designs were verified by the production practice.
基金Item Sponsored by Tianjin Natural Science Foundation of China(06YFJ MJC02200,11JCZDJC22600)
文摘Based on test data from the hot forge experiments on Gleeble 1500, a Kumar type constitutive equation for 33Mn2V steel is established. Applying this constitutive equation in commercial FEM software of MSC/SuperForm 2005, the piercing process of 33Mn2V steel in Mannesmann mill is then simulated. The modeling results visualized the dynamic evolution of equivalent stress, especially inside the workpieee. It is shown that the non-uniform distribu- tion of stress on the internal and external surface of the workpiece is a distinct characteristic of processing tube pierc- ing. The numerical model was verified by comparing the values of calculated force parameters of the piercing process with those measured in laboratory eonditions. And it shows that the Kumar-type constitutive relationship meets the practical needs.
基金Item Sponsored by the Innovation Fund for Outstanding Scholar of Henan Province of China (0621000700)
文摘The numerical simulation technique was applied to the casting process of a valve-type part. The mold-filling and solidification stages of the casting were numerically analyzed. The filling behavior, solidification sequence, and thermal stress distribution were reproduced and the possible defects, such as cold shut and shrinkage, were predicted. Based on the simulation result, the double-gating system was replaced by a single-gating system. Meanwhile, the chills were used to regulate the solidification sequence of casting. To eliminate the cracks in the casting, the sand core was converted into a canulate one. By modifying the original process, the defects were eliminated and the casting with good quality was obtained.
