Search Results (133)

The study focuses on the asymmetric shrinkage typically occurring between the upstream and downstream regions of FRP injection-molded products, a challenge that is particularly difficult to manage and improve. Specifically, two sets of four-cavity systems in one mold were utilized as the experimental platform. One set used a balanced runner (BR) system, and the other used a non-balanced runner (NBR) system. Each cavity in the four-cavity systems contained an ASTM D638 standard specimen with dimensions of 63.5 mm × 9.53 mm × 3.5 mm. Both CAE simulation and experimental methods were applied. The results show that the filling patterns from the simulation analysis closely matched those from the experimental study for both BR and NBR systems. Furthermore, by comparing the geometric shrinkage of the injected parts, significant differences were observed in the dimensional deformation in three directions (x, y, and z) between the NBR and BR systems. Specifically, at the end of the filling region (EFR), there was no noticeable difference in shrinkage along the flow direction, but the shrinkage in the cross-flow and thickness directions was reduced in the NBR system. Additionally, for the same cavity (1C) in both BR and NBR systems, the melt-rotation effect significantly reduced shrinkage in both the cross-flow and thickness directions. These findings strongly suggest that melt rotation can effectively modify the dimensional shrinkage of injection-molded parts. Moreover, fiber orientation analyses of the 1C cavity were also performed using CAE simulation for both BR and NBR systems. The results show that in the NBR system, the melt-rotation effect substantially alters the fiber orientation. Specifically, the fiber orientation tensors in the cross-flow (A₂₂) direction exhibit a decreasing trend. It can be speculated that the melt rotation alters the flow field, which subsequently changes the fiber orientation by reducing the flow-fiber coupling effect, thereby reducing the upstream-to-downstream asymmetry in the cross-flow direction. Through in-depth analysis, it is demonstrated that the correlation between the macroscopic geometric shrinkage and the microscopic fiber orientation changes is highly consistent. Specifically, in the EFR, ΔA₂₂ decreased by 0.0376, improving upstream/downstream shrinkage asymmetry in the cross-flow direction (Ly). Future work will investigate alternative melt-rotation designs and the optimization of model-internal parameters in FOD prediction. Full article

During electron beam cold hearth melting (EBCHM) of Ti-6wt%Al-4wt%V titanium alloy, aluminum volatilization causes compositional segregation in the ingot, significantly degrading material performance. Traditional methods (e.g., the Langmuir equation) struggle to accurately predict aluminum diffusion and compensation behaviors, while computational fluid dynamics (CFD), although capable of resolving multiphysics fields in the molten pool, suffer from high computational costs and insufficient research on segregation control. To address these issues, this study proposes a CFD-machine learning (backpropagation neural network, CFD-ML(BP)) approach to achieve precise prediction and optimization of aluminum segregation. First, CFD simulations are performed to obtain the molten pool’s temperature field, flow field, and aluminum concentration distribution, with model reliability validated experimentally. Subsequently, a BP neural network is trained using large-scale CFD datasets to establish an aluminum concentration prediction model, capturing the nonlinear relationships between process parameters (e.g., casting speed, temperature) and compositional segregation. Finally, optimization algorithms are applied to determine optimal process parameters, which are validated via CFD multiphysics coupling simulations. The results demonstrate that this method predicts the average aluminum concentration in the ingot with an error of ≤3%, significantly reducing computational costs. It also elucidates the kinetic mechanisms of aluminum volatilization and diffusion, revealing that non-monotonic segregation trends arise from the dynamic balance of volatilization, diffusion, convection, and solidification. Moreover, the most uniform aluminum distribution (average 6.8 wt.%, R² = 0.002) is achieved in a double-overflow mold at a casting speed of 18 mm/min and a temperature of 2168 K. Full article

By embedding optical fiber sensors into fiber preforms and utilizing liquid molding processes such as resin transfer molding (RTM), intelligent composite materials with self-sensing capabilities can be fabricated. In the liquid molding process of these intelligent composites, the quality of the final product is highly dependent on the resin flow and impregnation effects. The embedding of optical fibers can affect the microscopic flow and impregnation behavior of the resin; therefore, it is necessary to investigate the specific impact of optical fiber embedding on the resin flow and impregnation of fiber bundles. Due to the difficulty of directly observing this process at the microscopic scale through experiments, numerical simulation has become a key method for studying this issue. This paper focuses on the resin micro-flow in RTM processes for intelligent composites with embedded optical fibers. Firstly, a steady-state analysis of the resin flow and impregnation process was conducted using COMSOL 6.0 obtaining the velocity and pressure field distribution characteristics under different optical fiber embedding conditions. Secondly, the dynamic process of resin flow and impregnation of fiber bundles at the microscopic scale was simulated using Fluent 2022R2. This study comprehensively analyzes the impact of different optical fiber embedding configurations on resin flow and impregnation characteristics, determining the impregnation time and porosity after impregnation under different optical fiber embedding scenarios. Additionally, this study reveals the mechanisms of pore formation and their distribution patterns. The research findings provide important theoretical guidance for optimizing the RTM molding process parameters for intelligent composite materials. Full article

Resin Transfer Molding (RTM) is a widely used composite manufacturing process where liquid resin is injected into a closed mold filled with a fibrous preform. By applying this process, large pieces with complex shapes can be produced on an industrial scale, presenting excellent properties and quality. A true physical phenomenon occurring in the RTM process, especially when using vegetable fibers, is related to the absorption of resin by the fiber during the infiltration process. The real effect is related to the slowdown in the advance of the fluid flow front, increasing the mold filling time. This phenomenon is little explored in the literature, especially for non-isothermal conditions. In this sense, this paper does a numerical study of the liquid injection process in a closed and heated mold. The proposed mathematical modeling considers the radial, three-dimensional, and transient flow, variable injection pressure, and fluid viscosity, including the effect of liquid fluid absorption by the reinforcement (fiber). Simulations were carried out using Computational Fluid Dynamic tools. The numerical results of the filling time were compared with experimental results, and a good approximation was obtained. Further, the pressure, temperature, velocity, and volumetric fraction fields, as well as the transient history of the fluid front position and injection fluid volumetric flow rate, are presented and analyzed. Full article

During the continuous casting process, the submerged entry nozzle (SEN) should be maintained at the geometric center of the mold. However, in actual production, factors such as deformation of the tundish bottom and inaccurate positioning of the traversing car occasionally cause SEN offset. SEN offset can make the molten steel flow field in the mold asymmetric, increasing the risks of slag entrainment on the surface of the casting blank and breakout accidents. To evaluate the influence of different SEN offsets on the mold flow field, this study uses a slab continuous casting mold with a cross-section of 920 mm × 200 mm from a specific factory as the research object. Mathematical simulations were used to investigate the influence of SEN offsets (including width-direction and thickness-direction offsets) on the flow behavior of molten steel in the mold. A physical water model at a 1:1 scale was established for verification. Two parameters, the symmetry index (S) and the bias flow index (N), were introduced to quantitatively evaluate the symmetry of the flow field, and the rationality of the liquid-level fluctuation under this flow field was verified using the F-number (proposed by Japanese experts for mold level fluctuation control) from the index model. The results show the following: when the SEN offset in the thickness direction increases from 0 to 50 mm, the longitudinal symmetry index (Sy) of the molten steel flow field in the mold decreases from 0.969 to 0.704—a reduction of 27.4%; the longitudinal bias flow index (Ny) of molten steel level fluctuation increases from 0.007 to 0.186, representing a 25.6-fold increase, and the F-number rises from 4.297 to 8.482; when the SEN offset in the width direction increases from 0 to 20 mm, the transverse-axis symmetry index (Sx) of the flow field decreases gradually from 0.969 to 0.753 at a 20 mm offset, which is a reduction of approximately 22.29%; the transverse-axis bias flow index (Nx) increases from 0.015 to 0.174 at a 20 mm offset—an increase of 10.6 times; and the F-number increases from 4.297 to 5.548. Considering the comprehensive evaluation of horizontal/vertical symmetry indices, bias flow indices, and F-numbers under the two working conditions, the width-direction SEN offset has the most significant impact on the symmetry of the molten steel flow field. Full article

To address the challenges of unclear thermo-mechanical coupling mechanisms and unpredictable multi-field synergistic effects in segmented tire molds during vulcanization, this study focuses on segmented tire molds and proposes a multi-physics coupling numerical model. This model integrates fluid flow dynamics into heat transfer mechanisms. It systematically reveals molds’ heat transfer characteristics, stress distribution and deformation behavior under combined high-temperature and mechanical loading. Based on a fluid-solid-thermal coupling framework and experimental validations, simulations indicate that the internal temperature field of the mold is highly uniform. The global temperature difference is less than 0.13%. The temperature load has a significant dominant effect on the deformation of key components such as the guide ring and installation ring. Molding forces play a secondary role in total stress. The error between multi-field coupling simulation results and experimental results is controlled within 6%, verifying the model’s reliability. This research not only provides a universally applicable multi-field coupling analysis method for complex mold design but also highlights the critical role of temperature fields in stress distribution and deformation analysis. This lays a theoretical foundation for the intelligent design and process optimization of high-temperature, high-pressure forming equipment. Full article

Extrusion molding die heads play a critical role in film production, with their structure directly influencing product quality, production efficiency, and die life cycle. This study focused on optimizing the film blowing process by designing a new spiral die head and analyzing the flow field dynamics. The model was constructed via a three-dimensional Boolean operation following fluid mechanics principles to establish a mathematical model based on the die head’s structure and material properties. By varying parameters such as the inlet flow rate, buffer groove length, shaping section length, and non-Newtonian index, the velocity and pressure fields were analyzed using the finite element method. The results show that increasing the inlet velocity and non-Newtonian index significantly impacted the velocity uniformity, inlet and outlet pressure, and pressure drop. A higher inlet velocity led to increased fluctuations in outlet velocity and a higher inlet pressure, while a higher non-Newtonian index resulted in a more uniform outlet velocity and a reduced fluctuation, though with a higher inlet pressure and flow channel pressure drop. The lengthening of the buffer groove and shaping section had minimal effect on the outlet velocity uniformity but increased the inlet and outlet pressures and pressure drop at each stage. This study concluded that a uniform velocity distribution, lower pressure, and reduced energy consumption are crucial for high-quality film production. The optimal parameter values were found to be an inlet flow rate of 0.03 m/s, buffer groove length of 40 mm, shaping section length of 20 mm, and non-Newtonian index of 0.36. These findings provide a theoretical foundation for optimizing die head design and improving thin film quality in practical applications. Full article

As the core component of chain-less ammunition transmission system, the large long lead cylinder adopts ZL205A alloy, which has the advantages of high strength and wear resistance. However, in its main casting production process, the forming quality is mainly determined by the casting process parameters under the premise of determining a reasonable casting system. Considering that the casting process parameters are the process feedback expression of the macroscopic forming quality and comprehensive mechanical properties by controlling the coupling effect of the metal liquid flow in the microscopic flow field, the directional solidification crystallization of the alloy and the solid–liquid heat transfer and heat transfer during the filling and solidification process, the accurate and reasonable selection of casting process parameters is conducive to the stable guarantee of pouring quality. On the basis of the optimized column gap casting system, this study combined numerical simulation and data statistics. Within the rationality of each casting process parameter constructed by single-factor analysis, the response surface method was used to construct a quantitative guidance relationship of each process parameter coupling mapping casting defect, and based on this model, the optimal process parameter combination was realized as follows: compared with traditional metal mold casting and unoptimized low pressure casting, the tensile strength of non-porous casting with holding pressure 14.68 kPa, casting temperature 717.152 °C and mold preheating temperature 256.12 °C increased by 6.6% and 4.1%, respectively, hardness increased by 14.3% and 8.4% respectively, and the elongation is increased by 16.9% and 10.6%, respectively, thus efficiently and accurately improving the process quality. Full article

The ability to control and manipulate biological fluids within microchannels is a fundamental challenge in biological diagnosis and pharmaceutical analyses, particularly when buffers with very high ionic strength are used. In this study, we investigate the numerical and experimental study of fluidic biochips driven by ac electrothermal flow for controlling and manipulating biological samples inside a microchannel, e.g., for fluid-driven and manipulation purposes such as concentrating and mixing. By appropriately switching the voltage on the electrode structures and inducing AC electrothermal forces within the channel, a fluidic network with pumping and manipulation capabilities can be achieved, enabling the control of fluid velocity/direction and also fluid rotation. By using finite element analysis, coupled physics of electrical, thermal, fluidic fields, and molecular diffusion transport were solved. AC electrothermal flow was studied for pumping and mixing applications, and the optimal model was extracted. The microfluidic chip was fabricated using two processes: electrode structure development on the chip and silicon mold fabrication in a cleanroom. PDMS was prepared as the microchannel material and bonded to the electrode structure. After implementing the chip holder and excitation circuit, a biological buffer with varying ionic strengths (0.2, 0.4, and 0.6 [S/m]) was prepared, mixed with fluorescent particles, and loaded into the microfluidic chip. Experimental results demonstrated the efficiency of the proposed chip for biological applications, showing that stronger flows were generated with increasing fluid conductivity and excitation voltage. The system behavior was characterized using an impedance analyzer. Frequency response analysis revealed that for a solution with an electrical conductivity of 0.6 [S/m], the fluid velocity remained almost constant within a frequency range of 100 kHz to 10 MHz. Overall, the experimental results showed good agreement with the simulation outcomes. Full article

In view of the increasing demand for secondary aluminum, which is intended to partially replace the very energy- and resource-intensive primary aluminum production, effective treatment methods can maintain the high quality level of light metal castings. The transition from a linear to a circular economy can result in an accumulation of oxides or carbides in aluminum. Therefore, melt purification is crucial, especially as foundries aim to increase the use of often dirty end-of-life scrap. Nonmetallic inclusions in the melt can impact its flowability and mechanical properties. As the purity of the melt increases, its flow length also tends to increase. Available assessment methods like reduced pressure test or K-mold are capable of ensuring high levels of purity. This study demonstrates the implication of inclusions originating from dirty scrap. An experimental test run deals with various scrap contents in an AlSi7Cu0.5Mg alloy and shows correlations between impurity and performance, expressed by flowability and mechanical properties. These performance indicators have been connected to inclusion and porosity rates. In conclusion, these findings emphasize the need for further extensive research on contaminants in the field of scrap melting and the development of methods for easy-to-handle assessment methods. Full article

In this study, recycled acrylonitrile-butadiene-styrene terpolymer (ABSr) was reused to produce polyamide 6 (PA6)-based blends. This was achieved through reactive compatibilization using styrene-acrylonitrile-maleic anhydride (SAN-g-MA) copolymer with a high degree of functionalization (6–10% MA). The PA6/ABSr and PA6/ABSr/SAN-g-MA blends were prepared through melt processing and injection molding and then analyzed for their rheological, mechanical, thermomechanical, thermal, and structural properties, as well as morphology. The torque rheometry revealed a maximum reactivity of the PA6/ABSr (70/30 wt%) blend with low SAN-g-MA (5 phr—parts per hundred resin) content, while above this threshold, torque began to decline, indicating compatibilizer saturation in the interface. These findings were further substantiated by the increase in complex viscosity and the lower melt flow index (MFI) of the PA6/ABSr/SAN-g-MA (5 phr) blend. The 5 phr SAN-g-MA reactive compatibilization of the PA6/ABSr blends significantly enhanced its impact strength, elongation at break, tensile strength, and heat deflection temperature (HDT) by 217%, 631%, 12.6%, and 9.5%, respectively, compared to PA6/ABSr. These findings are promising for the plastic recycling field, paving the way for the production of new tailor-made materials at a reduced price. Full article

Water-powered projectile-assisted injection molding (W-PAIM) is a novel injection molding technology that has been recently developed based on the ripe water-assisted injection molding (WAIM). Fiber orientation pattern and residual wall thickness (RWT) are two crucial factors determining the quality of W-PAIM parts composed of short fiber-reinforced thermoplastics (SFRTCs). However, limited work has been conducted on W-PAIM of SFRTC parts, which restricts its application process. In this work, an intensive investigation of W-PAIM parts composed of short fiber-reinforced polypropylene was conducted via a newly lab-developed W-PAIM platform. The results indicated that fibers were quite well oriented in the region extending from the core zone to the water channel, especially in the water channel zone, but randomly aligned in a small region near the mold wall. Nevertheless, fibers in the water channel zone of W-PAIM part were highly oriented, presenting an opposite alignment trend in fiber orientation compared to that in the water channel zone of the WAIM part as reported earlier. These disparities in fiber orientation between W-PAIM and WAIM parts were primarily attributed to the strong flow fields generated by projectile penetration. Additionally, the influence of three main processing parameters that significantly affected the projectile penetration on these two crucial factors was also investigated using the single-factor method. It was discovered that water injection delay time constituted the primary factor affecting the projectile penetration process, and reducing this time could greatly increase the relative thickness of the ordered area and the uniformity of RWT. More importantly, within the value range of the tested processing parameters, increased water pressure, elevated melt temperatures, and shorter water injection delay time could simultaneously improve fiber orientation and the uniformity of RWT in W-PAIM parts, which may improve the properties of W-PAIM parts and enlarge their application scope. This work provides a comprehensive guide for the fabrication of W-PAIM parts of SFRTCs. Full article

Based on a physical water model with a scaling factor of 0.5 and a coupled flow–heat transfer–solidification numerical model, this study investigates the influence of the submerged entry nozzle (SEN) depth on the mold surface behavior, slag entrapment, internal flow field, temperature distribution, and initial solidification behavior in slab casting. The results indicate that when the SEN depth is too shallow (80 mm), the slag layer on the narrow face is thin, leading to slag entrapment. Within a certain range of SEN depths (less than 170 mm), increasing the SEN depth reduces the impact on the mold walls, shortening the “plateau period” of stagnated growth on the narrow face shell. This allows the upper recirculation flow to develop more fully, resulting in an increase in the surface flow velocity and an expansion in the high-temperature region near the meniscus, which promotes uniform slag melting but also heightens the risk of slag entrainment due to shear stress at the liquid surface (with 110 mm being the most stable condition). As the SEN depth continues to increase, the surface flow velocity gradually decreases, and the maximum fluctuation in the liquid surface diminishes, while the full development of the upper recirculation zone leads to a higher and more uniform meniscus temperature. This suggests that in practical production, it is advisable to avoid this critical SEN depth. Instead, the immersion depth should be controlled at a slightly shallower position (around 110 mm) or a deeper position (around 190 mm). Full article

To achieve uniform cooling and effective homogenization control in ultra-large beam-blank molds necessitates the optimization of submerged-entry-nozzle (SEN) structures. This study employed computational fluid dynamic (CFD) modeling to investigate the impact of two-port and three-port SEN configurations on fluid flow characteristics, free-surface velocities, temperature fields, and solidification behaviors. Subsequently, integrating numerical simulations with the non-dominated sorting genetic algorithm II (NSGA-II) and metallurgical quality-control expertise facilitated the multi-objective optimization of a three-port SEN structure suitable for beam-blank molds. The optimized parameters enabled the three-port SEN to deliver molten steel to the meniscus at an appropriate velocity while mitigating harmful effects such as SEN port backflow, excessive surface temperature differences, and shell thickness reduction due to fluid flow. The results indicated that the three-port SEN enhanced the molten-steel flow pattern and mitigated localized shell thinning compared with the two-port SEN. Additionally, the optimized design (op2) of the three-port SEN exhibited reduced boundary layer separation and superior fluid dynamics performance over the initial three-port SEN configuration. Full article

The agri-food processing industry predominantly relies on fossil fuels, contributing significantly to greenhouse gas emissions and extensive water use. Climate change requires a conversion of food processing technologies towards sustainability. Our research focuses on testing and validating pulsed electric field (PEF) technology as a mild processing method for stabilizing freshly squeezed, not from concentrate, blood orange juice. Experiments were carried out on a continuous pilot plant endowed with a patented treatment chamber that ensures a constant flow of product without “hot spots” for a homogeneous treatment. Once the operative conditions of the process in terms of energy density were optimized, PEF-treated blood orange juice was tested in order to evaluate the effects on physico-chemical parameters (total soluble solids, total acidity, pH, CIE L*, a*, b*, C*, h color indices, cloud, bioactive compounds (ascorbic acid, total anthocyanins, total and individual flavanones), antioxidant activity (ORAC units, total phenolic content), microbial communities (aerobic mesophilic viable count, yeasts and molds, acid-tolerant microorganisms), residual enzymatic pectinmethylesterase activity, and sensory attributes (flavor, off-flavor, off-odor, color, intensity of odor, acidity, sweetness, bitter, freshness, cooked flavor). Then, in order to simulate the commercial refrigerated distribution of PEF-treated blood orange juice and define its refrigerated shelf-life, the PEF-treated freshly squeezed, not from concentrate, blood orange juice was subjected to physico-chemical, antioxidant, microbiological, and sensory evaluations over twenty days of refrigerated storage at 4 ± 1 °C. The PEF treatment effectively ensured excellent microbial inactivation and enhanced the nutritional and health characteristics of the juice, thereby extending its shelf-life. This study demonstrates the significant potential of the PEF treatment to produce blood orange juice suitable for a new retail segment—freshly squeezed juices with superior health quality, fresh-like characteristics, and extended refrigerated shelf-life. Full article