Steel is a versatile material that has found widespread use because of its mechanical properties, its relatively low cost, and the ease with which it can be used in manufacturing process such as forming, welding and machining. Regarding to mechanical properties are strongly affected by grain size and chemical composition variations. Many industrial developments have been carried out both from the point of view of composition variation and grain size in order to exploit the effect of these variables to improve the mechanical proprieties of steels. It is also evident that grain growth are relevant to the mechanical properties of steels, thus suggesting the necessity of mathematical models able to predict the microstructural evolution after thermo cycles. It is therefore of primary importance to study microstructural changes, such as grain size variations of steels during isothermal treatments through the application of a mathematical model, able in general to describe the grain growth in metals. This paper deals with the grain growth modelling of steels based on the statistical theory of grain growth originally developed by Lücke  and here integrated to take into account the Zener drag effect and is therefore focused on the process description for the determination of the kinetics of grain growth curves temperature dependence.
The main aim of the presented research was to check mechanical response of human body model under loads that can occur during airplane accidents and compare results of analysis with some results of experimental tests described in literature. In simulations, new multi-purpose human body model, the VIRTHUMAN, was used. The whole model, as well as its particular segments, was earlier validated based on experimental data, which proved its accuracy to simulate human body dynamic response under condition typical for car crashes, but it was not validated for loads with predominant vertical component (loads acting along spinal column), typical for airplane crashes. Due to limitation of available experimental data, the authors focused on conducting calculations for the case introduced in 14 CFR: Parts 23.562 and 25.562, paragraph (b)(1), knowing as the 60 pitch test. The analysis consists in comparison of compression load measured in lumbar section of spine of the FAA HIII Dummy (experimental model) and in the Virthuman (numerical model). The performed analyses show numerical stability of the model and satisfactory agreement between experimental data and simulated Virthuman responses. In that sense, the Virthuman model, although originally developed for automotive analyses, shows also great potential to become valuable tool for applications in aviation crashworthiness and safety analyses, as well.
The paper presents the application of the newly developed method of the solution of nonlinear equations to the adaptive modelling and computer simulation. The approach is suitable when the system of equations can be arranged in such a way that it consists of a large number of linear equations and a smaller number of nonlinear equations. This situation occurs in the case of adaptive modelling of mechanical systems using finite elements or finite differences techniques. In this case the classical least square method becomes very effective. The paper presents several examples of the application of the method. A solution to the, so called, “black box” problem is also presented.
Metallographic investigations and a computer simulation of stresses in a gravity die-casting bushing were performed. Simulation of the casting process, solidification of the thick-walled bushing and calculations of the stress was performed using MAGMA5.3 software. The size variability of phases κIIaffecting the formation of phase stresses σf, depending on the location of the metallographic test area, was identified. The distribution of thermal σtand shrinkage stresses σs, depending on the location of the control point SC in the bushing's volume, was estimated. Probably the nature of these stresses will change slightly even after machining. This can cause variations in operating characteristics (friction coefficient, wear). Due to the strong inhomogeneity of the stress distribution in the bushing's casting, it is necessary to perform further tests of the possibility to conduct thermal treatment guaranteeing homogenization of the internal stresses in the casting, as well as to introduce changes in the bushing's construction and the casting technology. The paper presents the continuation of the results of research aimed at identifying the causes of defects in the thick-walled bushing, die-casting made of CuAl10Fe5Ni5Cr aluminium bronze.
The purpose of this study is to identify relationships between the values of the fluidity obtained by computer simulation and by an experimental test in the horizontal three-channel mould designed in accordance with the Measurement Systems Analysis. Al-Si alloy was a model material. The factors affecting the fluidity varied in following ranges: Si content 5 wt.% – 12 wt.%, Fe content 0.15 wt.% – 0.3wt. %, the pouring temperature 605°C-830°C, and the pouring speed 100 g · s–1 – 400 g · s–1. The software NovaFlow&Solid was used for simulations. The statistically significant difference between the value of fluidity calculated by the equation and obtained by experiment was not found. This design simplifies the calculation of the capability of the measurement process of the fluidity with full replacement of experiments by calculation, using regression equation.
Experiments of filling the model moulds cavity of various inner shapes inserted in rectangular cavity of the casting die (dimensions: 280 mm (height) x 190 mm (width) x 10 mm (depth) by applying model liquids of various density and viscosity are presented in the paper. Influence of die venting as well as inlet system area and inlet velocity on the volumetric rate of filling of the model liquid – achieved by means of filming the process in the system of a cold-chamber casting die was tested. Experiments compared with the results of simulation performed by means of the calculation module Novacast (Novaflow&Solid) for the selected various casting conditions – are also presented in the paper.
The article is a case study of the steel milling ring casting of about 6 tonnes net weight. The casting has been cast in the steel foundry the authors have been cooperating with. The aim was to analyse the influence of the shape of the chills and the material which was used to make them on the casting crystallization process. To optimally design the chills the set of the computer simulation has been carried out with 3 chills’ shape versions and 3 material’s versions and the results have been compared with the technology being in use (no chills). The proposed chills were of different thermal conductivity from low to high. Their shapes were obviously dependant on the adjacent casting surface geometry but were the result of the attempt to optimise their effect with the minimum weight, too. The chills working efficiency was analysed jointly with the previously designed top feeders system. The following parameters have been chosen to compare their effectiveness and the crystallization process: time to complete solidification and so-called fed volume describing the casting feeding efficiency. The computer simulations have been carried out with use of MagmaSoft v. 5.2 software. Finally, the optimisation has led to 15% better steel yield thanks to 60% top feeders weight reduction and 40% shorter solidification time. The steel ring cast with use of such technology fulfil all quality criteria.
The quantitative description of an airlift bioreactor, in which aerobic biodegradation limited by carbonaceous substrate and oxygen dissolved in a liquid takes place, is presented. This process is described by the double-substrate kinetics. Mathematical models based on the assumption of plug flow and dispersion flow of liquid through the riser and the downcomer in the reactor were proposed. Calculations were performed for two representative hydrodynamic regimes of reactor operation, i.e. with the presence of gas bubbles only within the riser and for complete gas circulation. The analysis aimed at how the choice of a mathematical model of the process would enable detecting the theoretical occurrence of oxygen deficiency in the airlift reactor. It was demonstrated that the simplification of numerical calculations by assuming the “plug flow” model instead of dispersion with high Péclet numbers posed a risk of improper evaluation of the presence of oxygen deficiency zones. Conclusions related to apparatusmodelling and process design were drawn on the basis of the results obtained. The paper is a continuation of an earlier publication (Grzywacz, 2012a) where an analysis of single-substrate models of the airlift reactor was presented.
CFD modelling of momentum and heat transfer using the Large Eddy Simulation (LES) approach has been presented for a Kenics static mixer. The simulations were performed with the commercial code ANSYS Fluent 15 for turbulent flow of three values of Reynolds number, Re = 5 000, 10 000 and 18 000. The numerical modelling began in the RANS model, where standard k−ε turbulence model and wall functions were used. Then the LES iterations started from the initial velocity and temperature fields obtained in RANS. In LES, the Smagorinsky–Lilly model was used for the sub-grid scale fluctuations along with wall functions for prediction of flow and heat transfer in the near-wall region. The performed numerical study in a Kenics static mixer resulted in highly fluctuating fields of both velocity and temperature. Simulation results were presented and analysed in the form of velocity and temperature contours. In addition, the surface-averaged heat transfer coefficient values for the whole insert length were computed and compared with the literature experimental data. Good compliance of the LES simulation results with the experimental correlation was obtained.
Rock excavation is a basic technological operation during tunnelling and drilling roadways in underground mines. Tunnels and roadways in underground mines are driven into a rock mass, which in the particular case of sedimentary rocks, often have a layered structure and complicated tectonics. For this reason, rock strata often have highly differentiated mechanical properties, diverse deposition patterns and varied thicknesses in the cross sections of such headings. In the field of roadheader technology applied to drilling headings, the structure of a rock mass is highly relevant when selecting the appropriate cutting method for the heading face. Decidedly differentiated values of the parameters which describe the mechanical properties of a particular rock layer deposited in the cross section of the drilled tunnel heading will influence the value and character of the load on the cutting system, generated by the cutting process, power demand, efficiency and energy consumption of the cutting process. The article presents a mathematical modelling process for cutting a layered structure rock mass with the transverse head of a boom-type roadheader. The assumption was made that the rock mass being cut consists of a certain number of rock layers with predefined mechanical properties, a specific thickness and deposition pattern. The mathematical model created was executed through a computer programme. It was used for analysing the impact deposition patterns of rock layers with varied mechanical properties, have on the amount of cutting power consumed and load placed on a roadheader cutting system. The article presents an example of the results attained from computer simulations. They indicate that variations in the properties of the rock cut – as cutting heads are moving along the surface of the heading face – may have, apart from multiple other factors, a significant impact on the value of the power consumed by the cutting process.
This article considers designing of a renewable electrical power generation system for self-contained homes away from conventional grids. A model based on a technique for the analysis and evaluation of two solar and wind energy sources, electrochemical storage and charging of a housing area is introduced into a simulation and calculation program that aims to decide, based on the optimized results, on electrical energy production system coupled or separated from the two sources mentioned above that must be able to ensure a continuous energy balance at any time of the day. Such system is the most cost-effective among the systems found. The wind system adopted in the study is of the low starting speed that meets the criteria of low winds in the selected region under study unlike the adequate solar resource, which will lead to an examination of its feasibility and profitability to compensate for the inactivity of photovoltaic panels in periods of no sunlight. That is a system with fewer photovoltaic panels and storage batteries whereby these should return a full day of autonomy. Two configurations are selected and discussed. The first is composed of photovoltaic panels and storage batteries and the other includes the addition of a wind system in combination with the photovoltaic system with storage but at a higher investment cost than the first. Consequently, this result proves that is preferable to opt for a purely photovoltaic system supported by the storage in this type of site and invalidates the interest of adding micro wind turbines adapted to sites with low wind resources.
The paper presents an approach of numerical modelling of alloy solidification in permanent mold and transient heat transport between the casting and the mold in two-dimensional space. The gap of time-dependent width called "air gap", filled with heat conducting gaseous medium is included in the model. The coefficient of thermal conductivity of the gas filling the space between the casting and the mold is small enough to introduce significant thermal resistance into the heat transport process. The mathematical model of heat transport is based on the partial differential equation of heat conduction written independently for the solidifying region and the mold. Appropriate solidification model based on the latent heat of solidification is also included in the mathematical description. These equations are supplemented by appropriate initial and boundary conditions. The formation process of air gap depends on the thermal deformations of the mold and the casting. The numerical model is based on the finite element method (FEM) with independent spatial discretization of interacting regions. It results in multi-mesh problem because the considered regions are disconnected.
The paper presents the evaluation of utility properties of a tube bend produced by bending process using local induction heating technique. Optimal process parameters were defined on the basis of numerical simulations. Mechanical testing procedures for the tube bend were carried out after normalising annealing. Heat treatment parameters have been chosen in compliance with the relevant standard. Geometrical measurements of the bend manufactured under industrial conditions indicate high accuracy of numerical simulations. Geometry and mechanical properties of the produced bend were consistent with the requirements of the applicable standards.
This paper presents the construction of adequate 3-D computer models for simulation research and analysis of dynamic aspects of caliper disc brakes, as well as of drum brakes, actuated by a short stroke electromagnet or a hydraulic thruster, when these brake types are used in the hoisting mechanism of cranes. The adequacy of the 3-D models has been confirmed by comparing their simulation results with results from an experiment and from classic computational models. The classic computational models, related to the study of main dynamic features of friction brakes, are layouts that are based on a number of assumptions, such as that the braking force instantly reaches its steady-state value, the clearance between the friction lining and the disc/drum is neglected, etc. These assumptions lead to a limitation of research options. The proposed 3-D computer models improve the research layouts by eliminating a number of the classic model assumptions. The improvements are related to the determination of the braking time, braking torque, normal force and other dynamic aspects of the brakes by performing simulations that take into account: the braking force as a function of time, the presence of clearance between the friction lining and the disc/drum, etc.
A hybrid artificial boundary condition (HABC) that combines the volume-based acoustic damping layer (ADL) and the local face-based characteristic boundary condition (CBC) is presented to enhance the absorption of acoustic waves near the computational boundaries. This method is applied to the prediction of aerodynamic noise from a circular cylinder immersed in uniform compressible viscous flow. Different ADLs are designed to assess their effectiveness whereby the effect of the mesh-stretch direction on wave absorption in the ADL is analysed. Large eddy simulation (LES) and FW-H acoustic analogy method are implemented to predict the far-field noise, and the sensitivities of each approach to the HABC are compared. In the LES computed propagation field of the fluctuation pressure and the frequency-domain results, the spurious reflections at edges are found to be significantly eliminated by the HABC through the effective dissipation of incident waves along the wave-front direction in the ADL. Thereby, the LES results are found to be in a good agreement with the acoustic pressure predicted using FW-H method, which is observed to be just affected slightly by reflected waves.