Numerical investigations of arc behaviour in gas metal arc welding using ANSYS CFX

Current numerical models of gas metal arc welding (GMAW) are trying to combine magnetohydrodynamics (MHD) models of the arc and volume of fluid (VoF) models of metal transfer. They neglect vaporization and assume an argon atmosphere for the arc region, as it is common practice for models of gas tungsten arc welding. These models predict temperatures above 20 000 K and a temperature distribution similar to tungsten inert gas (TIG) arcs. However, current spectroscopic temperature measurements in GMAW arcs demonstrate much lower arc temperatures. In contrast to TIG arcs they found a central local minimum of the radial temperature distribution. The paper presents a GMAW arc model that considers metal vapour and which is in a very good agreement with experimentally observed temperatures. Furthermore, the model is able to predict the local central minimum in the radial temperature and the radial electric current density distributions for the first time. The axially symmetric model of the welding torch, the work piece, the wire and the arc (fluid domain) implements MHD as well as turbulent mixing and thermal demixing of metal vapour in argon. The mass fraction of iron vapour obtained from the simulation shows an accumulation in the arc core and another accumulation on the fringes of the arc at 2000 to 5000 K. The demixing effects lead to very low concentrations of iron between these two regions. Sensitive analyses demonstrate the influence of the transport and radiation properties of metal vapour, and the evaporation rate relative to the wire feed. Finally the model predictions are compared with the measuring results of Zielińska et al.     

Numerical study of hydrogen explosions in a refuelling environment and in a model storage room

Numerical simulations have been carried out for large scale hydrogen explosions in a refuelling environment and in a model storage room. For the first scenario, a high pressure hydrogen jet released in a congested refuelling environment was ignited and the subsequent explosion analysed. The computational domain mimics the experimental set up for a vertical downwards release in a vehicle refuelling environment experimentally tested by Shirvill et al. [6]. For completeness of the analysis, an analytical model has also been developed to provide the transient pressure conditions at nozzle exit. The numerical study is based on the traditional computational fluid dynamics (CFD) techniques solving Reynolds averaged Navier-Stokes equations. The Pseudo diameter approach is used to bypass the shock-laden flow structure in the immediate vicinity of the nozzle. For combustion, the Turbulent Flame Closure (TFC) model is used while the shear stress transport (SST) model is used for turbulence. In the second scenario, premixed hydrogen-air clouds with different hydrogen concentrations from 15% to 60% in volume were ignited in a model storage room. Analysis was carried out to derive the dependence of overpressure on hydrogen concentrations for safety considerations.     

CFX模拟分解炉内CaCO3分解反应的研究

运用CFX模拟分解炉模型内的流动、煤粉燃烧、CaCO3的分解过程,对系统进行气体组分质量平衡和热量平衡计算,结果表明：O2的相对误差<3%,CO2的相对误差<9%,热量的相对误差<9%,表明用CFX模拟分解炉时的可靠性达90%以上;当计算参数如CaCO3量或煤粉量变化0.01%时,炉内温度分布、出口温度、CaCO3分解率等变量几乎没有变化,而当计算参数的变化量大于0.01%时,计算结果就看出变化,即CFX的模拟计算结果响应这两个计算参数变化的灵敏度可达到近万分之一。     

基于CFX软件设计离心压缩机三元叶轮

以某试验压缩机叶轮为模型,采用CFX软件设计三元叶轮,介绍了如何设计叶轮以及怎样通过调节叶轮的几何参数值改进叶轮,进而获得数值模拟中的高效率叶轮。     

微细磨料喷射加工仿真与实验研究

利用流体动力学仿真软件CFX对微细磨料喷射加工中,影响加工效果的喷射压力、喷射距离等影响因素进行仿真,模拟出不同参数下磨料微粒的速度、工件表面所受压力的分布规律,并与实验结果进行对比,验证仿真结果的正确性.     

矩形喷嘴对PDC钻头井底流场影响的研究

针对PDC钻头的水力能量清洗井底和冷却钻头的作用充分发挥的结构设计问题,先分析了矩形喷嘴的射流特性,得到了射流轴心动压力衰减规律和横向动压力分布规律及横向动压力梯度分布规律,通过CFD仿真软件CFX对PDC钻头井底流场进行了模拟,将矩形喷嘴和圆形喷嘴对比,分析得知喷嘴位置在等速核长度内,矩形喷嘴更有利于清除岩屑和冷却钻头。     

分布式能源用新型Senegal式垂直轴风力机尾流分析

针对现有的Jensen尾流模型分析水平轴风力机(HAWTs)的方法,对采用经典Jensen尾流模型时恒定的风速亏损和尾流衰减系数进行改进,提出基于改进型Jensen尾流模型对新型Senegal式垂直轴风力机(VAWTs)尾流分析的新方法.结合流场分析对该新型风力机进行尾流数值模拟,得出了基于改进的Jensen尾流模型的...     

基于微加速度计的虚拟呼啦圈

采用圆筒式换热器结构,建立了用于温差发电的尾气通道模型,运用流体仿真软件ANSYS CFX对其与尾气的换热效果进行仿真,分析不同翅片厚度、高度及翅片个数对换热性能的影响。根据不同尾气 速度下的模拟结果,确定了最佳翅片厚度、高度和翅片个数。计算结果表明,圆筒式换热器在减小尾气压降方面效果良好。     

带槽道桨水下机器人阻力特性的数值分析

自治水下机器人在低速航行时,单靠操舵方式难以保证其机动性。特别是作业过程中需要进行水下悬停定位时,经常会使用槽道桨。槽道桨在载体上形成贯穿式的孔洞结构,影响水下机器人直航过程中的阻力特性。本文借助流体动力数值仿真计算软件CFX,对槽道孔洞尺度改变、轴向位置改变时,水下机器人航行阻力所受到的影响进行了数值分析。数值分析得到的结论,对水下机器人槽道桨的工程设计和优化具有参考价值和指导作用。     

基于ANSYS CFX的注塑成型充填过程三维模拟

注塑成型中,熔体在模腔内的流动为非牛顿流体在复杂型腔内的非等温、非稳态流动。充填过程的三维数值模拟能更真实地模拟熔体在型腔内的三维流动状态。本文采用有限元分析软件ANSYS CFX进行二次开发,实现注塑成型充填过程的三维模拟,可求解熔体前沿、压力场、温度场等一系列模拟结果。模拟结果与注塑成型软件MOLDFLOW结果进行对比,验证了该方法的有效性。算例分析结果表明,对于薄壁制品,基于中面模型的注塑成型模拟方法是适用的,但对于非薄壁制品,采用三维模拟方法可以得到更合理更全面的信息。