NUMERICAL STUDY ON THE IMPORTANCE OF THE MIXED CONVECTION AND THE IMPACT OF THE COOLING RATE ON THE SOLIDIFICATION OF A PURE MATERIAL
DOI:
https://doi.org/10.4314/jfas.v11i3.10Keywords:
Solidification, Mushy zone, Melt flow, Free convection, Forced convection.Abstract
The present paper investigates numerically the solidification process of a pure metal, injected inside a channel, aiming to overview theoretically this complex phase change process, using COMSOL Multiphysics. The study is based on the Voller and Prakash model with fixed grid technique [1]. Results interpretation have been steered toward guessing the effect on the whole process of a varying entrance melt velocity; having proven that melt flow has a negative effect on the solidification rate. Also, the decreasing mid values of temperature transition (MVTT) would give fine numerical solution because it offers less thick mushy zone; this allows a good understanding to the solidification rate, mushy zone spreading and flow structure nearby solid region. Then, two different variable cooling rates functions were suggested comparing them to constant heat flux case. Results indicate that linear function cooling heat flux is the best function in terms of economy of cooling costs.
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References
[1] Voller V. R, Prakash C. A fixed grid numerical modeling methodology for convection-diffusion mushy region phase-change problems. Int. J. Heat Mass Transfer. (1987). Vol.30, No.8. pp 1709-1719.
[2] Thomas B.G, O’Malley R. J, Shi T, Meng Y, Creech D, Stone D. Modeling of Casting. Welding and advanced solidification process IX, Aachen, Germany. 20-25 Aug. 2000. TMS. Warrendale, PA, 2000, pp. 769-76.
[3] Hussainy Ferhathullah S, Viquar Mohiuddin M, Laxminarayana P, Sundarrajan S. Solidification simulation of aluminum alloy casting – A theoretical and experimental approach. International Journal of Modern Engineering Research (IJMER). (2015). Vol. 5, Feb, pp. 1-10
[4] Hameed H, Mohammed A. A, Fadhil O. T. Effect of cooling intensity and position on solidification in semi-continuous casting of copper. Open Journal of Fluid Dynamics. 6, 182-197.
DOI: 10.4236/ojfd.2016. 63015
[5] Kirpo M. Global simulation of the Czochralski silicon crystal growth in ANSYS Fluent (2013), J. Cryst. Growth 371 60–69.
DOI: http://dx.doi.org/10.1016/j.jcrysgro.2013.02.005
[6] Sengupta J, B. Thomas G, and Wells M. A. Understanding the Role Water-cooling Plays during Continuous Casting of Steel and Aluminum Alloys. MS&T Conference Proceedings, (New Orleans, LA), AIST, Warrendale, PA (2004).
[7] Elliott A.J, Tin S, King W.T, Huang S.C, Gigliotti M.F.X, and Pollock T.M. Directional Solidification of Large Superalloy Castings with Radiation and Liquid-Metal Cooling: A Comparative Assessment. Metallurgical and materials transactions A, (2004), vol. 35A,
[8] Duan Q, Tan F.L, Leong K.C. A numerical study of solidification of n-hexadecane based on enthalpy formulation. Journal of materials processing technology. (2002).120 249–258.
DOI: 10.10161/S0924-0136(01)01188-8
[9] Rajesh Rajkolhe, Khan J. G. Defects, Causes and Their Remedies in Casting Process, International Journal of Research in Advent Technology. (2014). Vol.2, No.3
[10] Prabhakara Rao P, Chakraverthi G, Kumar A.C.S, Srinivasa Rao G. Modeling and Simulation of Solidification in Alloy Steel Sand Castings, International Journal of Thermal Technologies. (2011). Vol.1, No.1. pp.121-127
[11] ZHANG Xing-guo , ZHANG Wen-xiao , JIN Jun-ze , J. W. Evans. Flow of Steel in Mold Region During Continuous Casting. Interntional Journal of Iron and Steel Research, 2007, 14(2): 30-35, 41.
[12] Mahmoudi J. and Fredriksson H. An experimental and numerical study on the modelling of fluid flow. Heat transfer and solidification in a copper continuous strip casting process. Materials transactions. The Japan institute of metals. (2003).Vol. 44, No. 9 pp. 1741 to 1751.
[13] Wu M, Vakhrushev A, Nummer G, Pfeiler C, Kharicha A and Ludwig A. Importance of Melt Flow in Solidifying Mushy Zone. The Open Transport Phenomena Journal, (2010). 2, 16-23
[14] Frank P. Incropera , David P. Dewitt, Theodore L. Bergman, Adrienne S. Lavine. Fundamentals of heat and mas trandfer. JOHN WILEY & SONS, 2007, pp. 929
[15] Pantankar S. Y. Numerical heat transfer and fluid flow. Hemisphere. Washington. DC (1980).
[16] Carman P. C. Fluid flow through granular beds. Trans. Inst. Chem. Engs 15. 150-156. (1937).
DOI: 10.1016/S0263-8762(97)80003-2.
[17] Shmueli H, Ziskind G, Letan R. Melting in a vertical cylindrical tube: numerical investigation an comparison with experimentsInt. J. Heat Mass Transfer 53 4082-4091. (2010).
[18] Voller V. R, Cross M, Markatos N. C. An enthalpy method for convection/diffusion phase changes. Inr. J. Num. Meth. Engng 24, 221-284. (1987).
[19] Karunesh K, Shukla A, Atul S, Pascal H B. Melting and solidification behaviour of phase change materials with cyclic heating and cooling. Journal of Energy Storage 15 274–282. (2018).
[20] COMSOL Multiphysics User’s Guide, Comsol, (2018). Http://www.comsol.com.
[2] Thomas B.G, O’Malley R. J, Shi T, Meng Y, Creech D, Stone D. Modeling of Casting. Welding and advanced solidification process IX, Aachen, Germany. 20-25 Aug. 2000. TMS. Warrendale, PA, 2000, pp. 769-76.
[3] Hussainy Ferhathullah S, Viquar Mohiuddin M, Laxminarayana P, Sundarrajan S. Solidification simulation of aluminum alloy casting – A theoretical and experimental approach. International Journal of Modern Engineering Research (IJMER). (2015). Vol. 5, Feb, pp. 1-10
[4] Hameed H, Mohammed A. A, Fadhil O. T. Effect of cooling intensity and position on solidification in semi-continuous casting of copper. Open Journal of Fluid Dynamics. 6, 182-197.
DOI: 10.4236/ojfd.2016. 63015
[5] Kirpo M. Global simulation of the Czochralski silicon crystal growth in ANSYS Fluent (2013), J. Cryst. Growth 371 60–69.
DOI: http://dx.doi.org/10.1016/j.jcrysgro.2013.02.005
[6] Sengupta J, B. Thomas G, and Wells M. A. Understanding the Role Water-cooling Plays during Continuous Casting of Steel and Aluminum Alloys. MS&T Conference Proceedings, (New Orleans, LA), AIST, Warrendale, PA (2004).
[7] Elliott A.J, Tin S, King W.T, Huang S.C, Gigliotti M.F.X, and Pollock T.M. Directional Solidification of Large Superalloy Castings with Radiation and Liquid-Metal Cooling: A Comparative Assessment. Metallurgical and materials transactions A, (2004), vol. 35A,
[8] Duan Q, Tan F.L, Leong K.C. A numerical study of solidification of n-hexadecane based on enthalpy formulation. Journal of materials processing technology. (2002).120 249–258.
DOI: 10.10161/S0924-0136(01)01188-8
[9] Rajesh Rajkolhe, Khan J. G. Defects, Causes and Their Remedies in Casting Process, International Journal of Research in Advent Technology. (2014). Vol.2, No.3
[10] Prabhakara Rao P, Chakraverthi G, Kumar A.C.S, Srinivasa Rao G. Modeling and Simulation of Solidification in Alloy Steel Sand Castings, International Journal of Thermal Technologies. (2011). Vol.1, No.1. pp.121-127
[11] ZHANG Xing-guo , ZHANG Wen-xiao , JIN Jun-ze , J. W. Evans. Flow of Steel in Mold Region During Continuous Casting. Interntional Journal of Iron and Steel Research, 2007, 14(2): 30-35, 41.
[12] Mahmoudi J. and Fredriksson H. An experimental and numerical study on the modelling of fluid flow. Heat transfer and solidification in a copper continuous strip casting process. Materials transactions. The Japan institute of metals. (2003).Vol. 44, No. 9 pp. 1741 to 1751.
[13] Wu M, Vakhrushev A, Nummer G, Pfeiler C, Kharicha A and Ludwig A. Importance of Melt Flow in Solidifying Mushy Zone. The Open Transport Phenomena Journal, (2010). 2, 16-23
[14] Frank P. Incropera , David P. Dewitt, Theodore L. Bergman, Adrienne S. Lavine. Fundamentals of heat and mas trandfer. JOHN WILEY & SONS, 2007, pp. 929
[15] Pantankar S. Y. Numerical heat transfer and fluid flow. Hemisphere. Washington. DC (1980).
[16] Carman P. C. Fluid flow through granular beds. Trans. Inst. Chem. Engs 15. 150-156. (1937).
DOI: 10.1016/S0263-8762(97)80003-2.
[17] Shmueli H, Ziskind G, Letan R. Melting in a vertical cylindrical tube: numerical investigation an comparison with experimentsInt. J. Heat Mass Transfer 53 4082-4091. (2010).
[18] Voller V. R, Cross M, Markatos N. C. An enthalpy method for convection/diffusion phase changes. Inr. J. Num. Meth. Engng 24, 221-284. (1987).
[19] Karunesh K, Shukla A, Atul S, Pascal H B. Melting and solidification behaviour of phase change materials with cyclic heating and cooling. Journal of Energy Storage 15 274–282. (2018).
[20] COMSOL Multiphysics User’s Guide, Comsol, (2018). Http://www.comsol.com.
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Published
2019-08-29
How to Cite
BOUZENNADA, T.; MECHIGHEL, F. NUMERICAL STUDY ON THE IMPORTANCE OF THE MIXED CONVECTION AND THE IMPACT OF THE COOLING RATE ON THE SOLIDIFICATION OF A PURE MATERIAL. Journal of Fundamental and Applied Sciences, [S. l.], v. 11, n. 3, p. 1188–1211, 2019. DOI: 10.4314/jfas.v11i3.10. Disponível em: https://jfas.info/index.php/JFAS/article/view/577. Acesso em: 30 jan. 2025.
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