Simulation Of Temperature Field Research Articles

Safety Evaluation for Fabricated Small Box Girder Bridges Based on Fuzzy Analytic Hierarchy Process and Monitoring Data.

During the operation of fabricated small box girder bridges, which face safety issues such as structural degradation and failure, there is an urgent need to propose a safety evaluation method to cope with the possible risks. This article quantitatively evaluates the safety state of a fabricated small box girder bridge in Wuhan City based on Fuzzy Analytic Hierarchy Process (FAHP) and structural health monitoring (SHM) data. Firstly, the FAHP model is established, and stress, deformation, and temperature are selected as evaluation factors. The safety thresholds of stress and deformation are determined by combining the industry specifications and the historical statistical patterns of the massive SHM data. The temperature field of the bridge is simulated and analyzed by combining ANSYS, HYPERMESH, and TAITHREM, and the most unfavorable temperature gradient is determined as a threshold for the safety evaluation. Finally, the scores of indexes of the bridge are determined based on the measured SHM data, which in turn provides a quantitative description of the safety state. The results show that the thresholds determined by the joint industry specifications and the massive SHM data are reasonable; the temperature field simulation model established in this article is consistent with the measured results, and can accurately determine the temperature gradient of the bridge. The safety evaluation result from the FAHP model is the same as the field test results, which verifies the effectiveness and applicability of the proposed method to actual bridge projects.

A universal AC electrokinetics-based strategy toward surface antifouling of underwater optics

The practical applications of underwater optical devices, such as cameras or sensors, often suffer from widespread surface biofouling. Current antifouling techniques are primarily hindered by low efficiency, poor compatibility, as well as environmental pollution issues. This paper presents a transparent electrode coating as antifouling system of underwater optics as potential substitute for alternating current electrokinetic (ACEK)-based systems. A strong-coupling model is established to predict the Joule heating induced fluid flows and the negative dielectrophoretic (nDEP) effect for mobilizing organisms or deposited sediments on optic surfaces. The performance of the proposed antifouling system is numerically evaluated through simulations of electrostatic, fluid and temperature fields as well as trajectories of submicron particles, which is then experimentally verified and found to be in good agreement. A parametric study revealed that the degree of electrodes asymmetry is the key factor affecting the flow pattern and therefore the overall performance of the system. This ACEK-based universal strategy is expected to shed light on designing high performance and non-toxic platforms toward energy-efficient surface antifouling applications of underwater optics.

Microstructure and properties of Cr12MoV cold work mold steel repaired by wire arc additive manufacturing

The build-up welding repair belongs to the typical wire arc additive manufacturing technology, and can effectively repair the mold, significantly extend the life of the mold, is widely used in the field of mold repair. In this study, Cr12MoV cold work mold steel was repaired using wire arc additive manufacturing. Three build-up welding layers Ni625 (Inconel 625) layer, D322 (CrWMoV steel) layer, and Ni625/D322 double-layer composite build-up layer were designed on the Cr12MoV surface. Temperature field simulation and thermodynamic simulation calculations were used to provide the theoretical basis for microstructural analysis of the build-up welding specimens. The practicality of D322 build-up joint is best. The microstructure of D322 build-up joint is D322 layer (acicular martensite)/PHZ (the fusion zone)/HAZ (the heat-affected zone) Ⅰ (Ld + carbides)/HAZ Ⅱ (martensite + residual austenite + carbides (primary + spherical)/HAZ Ⅲ (martensite + lower bainite)/HAZ Ⅳ (tempered sorbite)/BMZ (the base material). The gradient of hardness distribution in different zones of the D322 build-up joint is the smallest, and the hardness of martensite D322 layer is the highest (702 HV), with the best wear resistance (the friction coefficient and the mass loss are lowest). Moreover, D322 build-up joints in the D322 layer and HAZ Ⅱ brittle fracture, shear strength of 464 MPa. The application of this technology can effectively repair Cr12MoV cold work mold steel and provide guidance for the mold repair industry.

Modeling and simulation of temperature field in high-shear and low-pressure grinding with liquid-body-armor-like grinding wheel

High-shear and low-pressure grinding using liquid-body-armor-like grinding wheel is a new grinding process. It has a great potential in the field of precision and ultra-precision machining. To clarify the unclear grinding heat characteristics, heat generation mechanism, and heat source distribution of the liquid-body-armor-like grinding wheel, a temperature field model was developed for high-shear and low-pressure grinding with ABAQUS. The thermal characteristics of the new grinding wheel were investigated by studying the heat flux and convective loads under different grinding parameters. The effectiveness of the heat model was validated through high-shear and low-pressure grinding experiments. The simulation results closely matched with the experimental results, with an average error of 5.84 % and a minimum error of 0.94 %. The grinding temperature decreased gradually from the centre of the heat source towards the edge of the workpiece in both horizontal and vertical directions. The temperature raised with the increase of the grinding velocity, ranging from 39.66 °C at 4 m/s to 77.82 °C at 14 m/s. It decreased with the workpiece feed rate, dropping from 39.66 °C at 500 mm/min to 32.00 °C at 3000 mm/min. As the normal grinding force increased, it gradually increases from 30.80 °C to 39.66 °C. The grinding temperature of the liquid-body-armor-like grinding wheel was lower than that of the traditional grinding wheel.

Simulation and verification of cylinder head’s temperature field for marine low-speed engine

Abstract The high load capacity of marine low-speed engines poses a challenge to the thermal load of the cylinder head and temperature field simulation can guide its structural design and optimization. The 3-dimensional models of the fluid domain for the cooling water and the solid domain for the cylinder head are established and meshed, the fluid domain model is simulated to research the heat transfer pattern by Fluent software, and the surface temperature and heat transfer coefficient of the cooling water is calculated. The thermal boundary conditions of the gas in the cylinder are simulated through the analysis of the engine working process. The temperature of the cylinder head is calculated based on the fluid-structure interaction model with the thermal boundary conditions by Workbench software. The validation of the model is carried out by comparing the simulated and measured temperature data in the heated inner wall of the cylinder head. The research results show that compared with the measured value, the error of simulation results is small, which shows that the model and method are reasonable. The temperature in the inner wall of the combustion chamber is low, which can provide possibilities to appropriately improve the power density of the low-speed engine and reduce the risk of low-temperature corrosion.

Research on tunnel vehicle fire temperature field simulation considering the latent heat of vaporization inside concrete linings

The high temperatures and non-uniform temperature fields caused by fires can lead to the rapid failure of linings, severely affecting tunnel safety. To obtain the temperature distribution of the lining under different fire conditions, simulation research is conducted by CFD technology. First, the fire resistance test of lining is simulated, and a furnace temperature simulation method based on PID control and a lining heat transfer model considering the latent heat of vaporization (LHV) are proposed. Second, the experimentally verified method is applied to a full-scale tunnel model to study the vehicle fire temperature field considering the LHV. The results show that the method based on the PID control can accurately simulate the furnace temperature. By introducing a LHV energy source, the 100 °C temperature plateau within the lining can be effectively simulated to prevent prematurely determining component failure. Compared to traditional methods, the lining-gas heat exchange boundary considering the LHV is more accurate. The temperature rise at the lining surface and rebar is slower, with maximum temperature differences of 80 K and 125 K, respectively. The aim of this research is to provide a complete temperature rise and fall process for the fire protection analysis and design of tunnel linings.

Prediction of geothermal temperature field by multi-attribute neural network

Hot dry rock (HDR) resources are gaining increasing attention as a significant renewable resource due to their low carbon footprint and stable nature. When assessing the potential of a conventional geothermal resource, a temperature field distribution is a crucial factor. However, the available geostatistical and numerical simulations methods are often influenced by data coverage and human factors. In this study, the Convolution Block Attention Module (CBAM) and Bottleneck Architecture were integrated into UNet (CBAM-B-UNet) for simulating the geothermal temperature field. The proposed CBAM-B-UNet takes in a geological model containing parameters such as density, thermal conductivity, and specific heat capacity as input, and it simulates the temperature field by dynamically blending these multiple parameters through the neural network. The bottleneck architectures and CBAM can reduce the computational cost while ensuring accuracy in the simulation. The CBAM-B-UNet was trained using thousands of geological models with various real structures and their corresponding temperature fields. The method’s applicability was verified by employing a complex geological model of hot dry rock. In the final analysis, the simulated temperature field results are compared with the theoretical steady-state crustal ground temperature model of Gonghe Basin. The results indicated a small error between them, further validating the method's superiority. During the temperature field simulation, the thermal evolution law of a symmetrical cooling front formed by low thermal conductivity and high specific heat capacity in the center of the fault zone and on both sides of granite was revealed. The temperature gradually decreases from the center towards the edges.

Coupled modeling of thermal-fluid-solid and chemo-mechanical behaviors in thermal barrier coatings under flowing gas environment

This study proposes a modeling approach to simulate the thermo-chemo-mechanical responses of thermal barrier coatings (TBCs) exposed to flowing high-temperature gas. A thermal-fluid-solid analysis was performed to simulate temperature fields of the coatings under flowing gas environment, while finite element analysis was carried out to study the oxidation and stress evolutions of the coatings using a developed chemo-mechanical constitutive model. Thermal loads from thermal-fluid-solid analysis were imposed on the finite element model, by which the factors associated with flowing gas were incorporated into the thermo-chemo-mechanical modeling. The study systematically investigated the effects of flowing gas and coolant on the chemo-mechanical responses of the coatings. The results revealed that the enhanced gas factors (temperature, velocity, angle of attack, and pressure) and coolant temperatures accelerate oxidation and induce higher residual stresses, while higher coolant velocity mitigates both oxidation and stresses. The volume fraction of oxygen in the gas was found to have a negligible influence. Dimensional analysis and multiple regression were performed to derive mathematical expressions for assessing out-of-plane stress and oxidation dynamics. Design maps were proposed to guide the durable design of the coatings.

Revealing the mechanism of superimposing ultrasonic vibration on microstructure evolution in friction stir welding by multi-physical multi-scale simulation

Ultrasonic vibration-enhanced friction stir welding (UVeFSW) is a promising joining method for aluminum‑lithium (Al-Li) alloy. However, directly observing the microstructural evolution in UVeFSW only by experimental methods is still a challenge. The mechanism of ultrasonic vibration (UV) on the microstructure evolution during FSW of Al-Li alloy remains unrevealed. In this study, a multi-physical multi-scale model was developed by coupling the finite element (FE) method and the Monte Carlo (MC) method to quantitatively study the impact of superimposing UV on the microstructure evolution in FSW. The preheating effect, acoustoplastic effect and residual hardening effect of UV were all considered in the model. Welding thermal processes, microstructure evolution of the material on the advancing side (AS) and in the center of the weld were quantitatively analyzed. And dislocation density and grain size in UVeFSW and FSW of Al-Li alloy were compared. Temperature field simulation results show that superimposing UV on FSW has a certain preheating effect in front of the tool. Microstructure simulation results show that the main effect of UV on microstructure evolution is the dynamic recrystallisation (DRX) process, where the maximum dislocation density in the weld nugget zone (WNZ) increases from 2.49 × 1013 m−2 to 3.49 × 1013 m−2 after superimposing UV, leading to an increase in the plastic deformation stored energy. Thereby, the driving force for nucleation and DRX increases, resulting in more nuclei in the WNZ, together with an increase in the width of the WNZ. Superimposing ultrasonic vibration in FSW can significantly refine the grain size by enhancing the activity and multiplication of dislocation in the UVeFSW of Al-Li alloy. The model is validated by the experimental results.

Uniformizing the temperature of turbine blades during the heat treatment process from the perspective of radiation energy distribution

Nickel-based single-crystal turbine blades are critical components of jet engines. Due to element segregation and microstructural defects in as-cast blades, vacuum heat treatment is essential. Controlling the blades’ heat treatment temperature is crucial for improving mechanical performance. However, when treating multiple blades simultaneously, large temperature differences often occur, making it challenging to ensure consistent and uniform temperatures. This paper establishes a numerical algorithm that links blade temperature with radiant energy, optimizing blade arrangement to achieve uniform energy distribution and temperature field homogenization. The improved view factor finite element algorithm is more suitable for blade structures. The Particle Swarm Optimization (PSO) and Coordinate Descent (CD) methods were used to solve the optimization function, aiming to minimize the temperature difference among blades. Finite element simulation was utilized to model the temperature field of the blades during radiative heat transfer from heating elements. The PSO and CD optimization methods were employed to find the local optimal solution that minimizes the view factor variance, reducing it from 2.24 before optimization to about 1. Simultaneously, the optimized maximum average temperature difference of the blades was 71.1 °C, approximately 50 % lower than the 138.8 °C before optimization. By comparing the view factor values with the simulated temperature fields, the strong correlation between the view factor and blade temperature was verified. This paper innovatively proposes a numerical method for optimizing blade arrangement to homogenize the temperature field, effectively enhancing temperature consistency during the heat treatment process.

Numerical simulation of melt flow and temperature field during DC casting 2024 aluminium alloy under different casting conditions

Numerical simulation of melt flow and temperature field during DC casting 2024 aluminium alloy under different casting conditions

Influence of ultrasonic excitation on the melt pool and microstructure characteristics of Ti-6Al-4V at powder bed fusion additive manufacturing solidification velocities

Cavitation and acoustic streaming created by in situ high-intensity ultrasound have been exploited for microstructural refinement during directed energy deposition (DED) additive manufacturing (AM) of alloy Ti‐6Al‐4V. Whether the same ultrasound-driven mechanisms are applicable to powder bed fusion (PBF) of Ti‐6Al‐4V remains uncertain. The primary factors that control the microstructure during deposition processing are the solidification velocity and temperature gradient, which are orders of magnitude higher for PBF than DED processes. This work examines the role of high-intensity ultrasound on the melt pool and resulting microstructure of Ti‐6Al‐4V under PBF solidification conditions. The effect of the laser scanning velocity and ultrasonic excitation on the melt pool and grain structure characteristics is interrogated through controlled line scans and area scans without powder. Temperature field simulations are used to estimate the solidification velocities and temperature gradients and to compare the processing conditions with previously characterized columnar-to-equiaxed transition diagrams. The acoustic pressures during processing are estimated using a coupled field acoustic-elastic finite element simulation and used in a Keller-Miksis model to assess the likelihood of cavitation vs. cavity size. The microstructure of the samples with or without ultrasonic excitation was characterized, allowing the equivalent grain diameters and aspect ratios to be compared. All samples, including those exposed to scanning velocities where cavitation did not occur, showed a reduction in grain aspect ratio when subjected to ultrasonic excitation, but the effect on equivalent grain diameter was inconclusive. A key finding is that the primary effects of ultrasonic excitation may be attributed to acoustic streaming, rather than cavitation, during PBF processing. Further development of the ultrasonic excitation technique explored may permit tailoring of the microstructure and texture characteristics in bulk AM parts.

Simulation of thermal field in mass concrete with cooling pipes based on the isogeometric analysis method

As the water pipe cooling system is widely applied to controlling temperature in mass concrete structures, the precise simulation of the temperature field in mass concrete with cooling pipes embedded is meaningful. This paper presents an isogeometric analysis (IGA) with NURBS for heat transfer in mass concrete with consideration of the cooling pipe. The proposed method not only achieves the same level of accuracy with fewer nodes but also eliminates the time-consuming process of mesh in the traditional FEM. The coarsest parameter space which depicts small pipe and large concrete precisely is constructed to create an efficient model for numerical computation. In addition, the unique k-refinement in IGA is supposed to be the most appropriate encryption mechanism, and the knot insertion vector for effective refinement is calculated by considering the characteristics of temperature gradient distribution around the cooling pipes. In addition, a different calculation parameter has been discussed to show the stability and flexibility of the IGA. The obtained numerical results demonstrate the accuracy and efficiency of the proposed scheme in the simulation of transient temperature fields in concrete structures with cooling systems.

Simulation and Analysis of Temperature and Pressure Fields in the Wellbore of Self-Injection Well

Aiming at the problem of wellbore waxing in high-temperature, high-pressure and highly-waxed deep gas condensate reservoirs, a wellbore temperature/pressure field prediction model for self-injection wells was established with the site parameters of the Bozi gas condensate field in the Tarim Basin of China using the OLGA software. With the help of the parameters of example wells on site in the Bozi, wellbore temperature and pressure in the process of gas extraction from 10 self-injector wells were predicted, and the following findings were obtained: the temperature decreases gradually in the process of condensate gas well lifting, and the slopes of the temperature profile shown an overall The overall slope of the temperature profile shown a trend of gradually becoming larger, indicating that the temperature drop was increasing, and the single wells in the block reflect similar wellbore temperature profile characteristics. During the lifting process, the pressure gradually decreases, and the slope of the pressure profile does not change significantly, indicating that the pressure drop along the way was relatively constant, and the single wells in the block reflect similar wellbore pressure field distribution characteristics. Combining the temperature gradient and pressure gradient interpretation data of different wells and time interfering test wells in Bozi, and using them as the basis for temperature and pressure profile regression, the above 10 condensate wells in Bozi block were classified according to different temperatures and pressures, and the temperature and pressure profiles were regressed and fitted to fit the actual working conditions, which lays a data basis for the analysis of wax formation in the example wells in Bozi.

Determination of beam oscillating pattern for tailoring melt flow and microstructural characteristics of laser welded Ti–6Al–4V alloy

The trajectory of beam is highly correlated to the heat distribution and fluid flow within the melting pool in laser welding, which has a great impact on improving the joint microstructure. This study employs fluid simulation techniques to investigate the temperature distribution and flow behavior of Ti–6Al–4V alloy under three laser oscillation welding patterns including none oscillation, sinusoidal oscillation, and circular oscillation, and the optimal oscillating pattern was determined through an analysis of microstructure characteristics. Temperature field simulation results indicate that the oscillation of the beam is efficaciously utilized to diminish the concentrated heat distribution on the base material. Moreover, a manifest difference in energy density and the area of laser action is produced, which leads to variations in the location and depth of the distribution of keyholes. Under circular oscillation, the flow behavior is more pronounced, with peak flow velocity increasing by approximately 80 % compared to none oscillation and new vortices were created in the horizontal section at the end of an oscillation period. Furthermore, compared to none oscillation and sinusoidal oscillation, the lower cooling rate under circular oscillating pattern contributes to the formation of equiaxed grains. The fine equiaxed grains are easy to move and form an ordered lattice structure, which favors the transformation of low-angle grain boundaries and the increase in the strength of the crystal texture. Therefore, with oscillation frequency and amplitude set at 80 Hz and 0.8 mm, respectively, the use of circular oscillating pattern in laser welding results in an improvement in weld seam microstructure.

The Microstructure characteristic and Its influence on the stray grains of Nickel-based single crystal superalloys prepared by Laser directed energy deposition

The microstructure adjustment and the stray grains inhibition are important for the preparation of Nickel-based single crystal (SX) superalloys by laser directed energy deposition (L-DED). In this work, the single channel monolayer and single channel five-layers DD6 SX superalloys have been prepared by L-DED. The macroscopic simulations in the deposition processing and multiscale characterizations of deposition structure were used to analyze the formation and evolution mechanisms of unique precipitations and stray grains. Results shows that the larger laser power and higher powder feed rate have a positive impact on the epitaxial growth of columnar dendrite and the elimination of stray grains. The residual stress caused by the complex thermal cycles is not the direct reason that induce the formation of SGs, but the rapid movement of dislocations result in the formation of sub-grain boundary. According to the columnar transition to equiaxed theory (CET), temperature field simulation and analysis of element segregation behaviors, the element segregation results in the unique microstructure, include petal-shaped γ/γ′ eutectic and demarcation band with a thickness of a single γ/γ′ eutectic. Besides, the geometric size of γ/γ′ eutectic decrease with respect to the deposition height. With the change of height at deposition region, dendritic orientation deviations affect the uniformity of element segregation, resulting in variations in γ′ phase and γ/γ′ eutectic dimensions between dendritic core and the inter-dendrite zone at the microscopic level and manifesting as grain boundaries at the mesoscale. At the same time, the formation mechanisms of carbide and adjacent γ/γ′ eutectic leads to the misorientations between the dendrite core and the inter-dendrite zone, which also appears as stray grains at the mesoscopic scale.

Numerical simulation of temperature field of a new type of freezing device under seepage effect.

In order to investigate the development of the temperature field of a new type of freezing reinforcement under seepage conditions, in this paper, COMSOL finite element software was used to simplify the model and simulate the effect of groundwater seepage on the development of the temperature field of frozen pipes by coupling the Darcy's law module and the heat transfer module for porous media. The heads of water were also varied to simulate the change in seepage velocity to further investigate the effect of seepage velocity on the temperature field. The results of the study show that the freezing wall formed in the high head region was thinner than that in the low head region due to the effect of seepage, and this phenomenon was aggravated with the increase of seepage rate; The effect of seepage action on the temperature field had a hysteresis along the seepage direction; When the seepage rate was greater than 1.65 m/d, the soil in the center of the device feezed better and could form a tight and dense freezing wall comparable to the size of the freezing device; When the seepage rate was greater than 5.78 m/d, the temperature of the center soil body gradually increased, and eventually the freezing curtain cannot be formed.

Simulation of temperature field in steel billets moving in the reheating furnace by a meshless method

A simulation of a reheating furnace in a steel production line where the steel billets are heated from room temperature up to 1200 °C is carried out. In this work, governing equations are solved in a strong form by the meshless local radial basis function collocation method (LRBFCM) with explicit time-stepping. The solution of the diffusion equation for the temperature is formulated on a two-dimensional central slice of the billet. The temperature field is solved by considering the positions of multiple billets in the furnace and the radiative and convective heat fluxes on the boundaries of the furnace and the billets. Ray tracing procedure, in which the view factors are computed with a Monte-Carlo method, is employed to determine the radiative heat flux. A sensitivity study is performed on the influence of two different stopping times of the billets in the furnace on the temperature evolution.

Study on the error characteristics of transformer for primary and secondary fusion used in pole-mounted switchgear

The fusion of primary and secondary functions refers to integrating the function of primary equipment and secondary equipment together. If doing so, the working condition of the equipment for primary and secondary fusion becomes more and more complex and bad, especially the transformer working in the smaller workspace after fusing. Therefore, this paper focuses on the transformer used in primary and secondary fusion pole-mounted Switchgear and establishes the temperature field and electric field simulation model of the primary and secondary fusion pole-mounted switchgear transformer, respectively, and the temperature rise and the environment electric field interference influencing the error of transformer are analyzed as well. When the working environment temperature ranges from -40 to 70°C, the maximum error of low-power current transformers and resistive voltage transformers is 0.1246% and 0.0371%, respectively. The electric field is one of the main factors influencing resistive voltage transformers, which makes ratio errors and angle errors -0.256% and -22.5392’, respectively. The research reveals that under conditions, the error is mainly dependent on temperature rise and electric field. These two factors have a great influence on the error, while the transformers still have enough reliability.

Numerical simulation of welding residual stresses in 6082-T6 thin aluminum alloy

Thin plate aluminum alloys of the 6082 series are widely used in welded car bodies because of their excellent characteristics such as light weight and high strength. For welded joints, residual stresses significantly affect fatigue strength properties, especially in thin plate welding. In this study, the residual stresses arising from inert gas welding of thin sheet aluminum alloy metals were investigated using numerical simulation techniques. The thermo-elastic–plastic method was used to calculate simulated weld temperature and stress fields. Temperature and stress variations during the welding process were discussed to investigate the causes of residual stresses. The changes in stress during the experimental welding process were tracked, and the results were in agreement with the simulations. The impact of process parameters on welding stress was analyzed through simulation and experimentation. The results showed that residual stress decreases as speed increases and increases as power increases.