Beruflich Dokumente
Kultur Dokumente
ICHMT-02110; No of Pages 6
A. Abbas Nejad a, M.J. Maghrebi a, H. Basirat Tabrizi b,, Y. Heng c, A. Mhamdi c, W. Marquardt c
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a
b
c
Department of Mechanical Engineering, Shahrood University of Technology, P.O. Box 3619995161-316, Shahrood, Iran
Department of Mechanical Engineering, Amirkabir University of Technology, P.O. Box 15875-4413, Tehran, Iran
AVT-Process Systems Engineering, RWTH Aachen University, D-52056 Aachen, Germany
i n f o
a b s t r a c t
RO
a r t i c l e
A transient nonlinear inverse heat transfer problem arising from alloy solidication processes is considered.
In practice, the solidus and liquidus interface motions and thus the mushy zone thicknesses are pre-given to
control the material quality. To achieve the desired front motions, the required time-dependent boundary
conditions have to be predicted on both mold sides simultaneously. In this study, the enthalpy method is
used for the derivation of governing equations. Hence, the inverse problem will be solved only in a single
spatial and temporal domain. The conjugate gradient method with adjoint equation is applied for the
resulting minimization problem. The method is applied as comparison for pure material with other previous
studies. Then, alloy material with different front velocities is set up to investigate the solidication process.
The obtained results show a close agreement between the desired and computed front motions and mushy
zone thickness.
2010 Elsevier Ltd. All rights reserved.
DP
Keywords:
Inverse heat Transfer
Alloy solidication
Conjugate gradient
Mushy zone thickness
TE
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1. Introduction
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RR
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CO
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UN
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EC
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OF
Please cite this article as: A. Abbas Nejad, et al., Int. Commun. Heat Mass Transf. (2010), doi:10.1016/j.icheatmasstransfer.2010.03.002
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A. Abbas Nejad et al. / International Communications in Heat and Mass Transfer xxx (2010) xxxxxx
T1:1
Nomenclature
T1:2
T1:3
T1:4
T1:5
T1:6
T1:7
T1:8
T1:9
T1:10
T1:11
T1:12
T1:13
T1:14
T1:15
T1:16
T1:17
T1:18
T1:19
T1:20
T1:21
T1:22
a
b
c
d
e
fs
H
k
L
q
s
Ste
t, tf
T
Tf
Tliq
Tsol
T0
V
x
T1:23
T1:24
T1:25
T1:26
T1:27
T1:28
T1:29
T1:30
T1:31
T1:32
T1:33
Greek symbols
small variation
threshold parameter
Lagrange multiplier
conjugate coefcient
adjoint variable
measurement error
s[q(t)] objective function gradient
T1:34
T1:35
T1:36
T1:37
T1:38
T1:39
subscripts
i
initial value
l
liquid phase
RMS
root mean square
s
solid phase
T1:40
T1:41
T1:42
superscripts
k
iteration number
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89
90
91
92
93
94
95
96
97
98
99
100
101
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123
124
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RO
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x=
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111
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x
t
TTf P
H
;
;H =
; t = 2l ; T =
Tf T0
a
cl Tf T0
a
L
qt a
k
;q=
;k =
cl Tf T0
kl Tf T0
kl
TE
Ste =
RR
EC
where, a is the mold length, Tf, Tsol and Tliq are fusion, solidus and 128
129
liquidus temperatures and L is the latent heat of the fusion. l, Cpl and 130
CO
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102
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UN
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Please cite this article as: A. Abbas Nejad, et al., Int. Commun. Heat Mass Transf. (2010), doi:10.1016/j.icheatmasstransfer.2010.03.002
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A. Abbas Nejad et al. / International Communications in Heat and Mass Transfer xxx (2010) xxxxxx
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T
=
kT
t
x
x
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T
x
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138
T
x
x=0
= qs t
0 b x b b 0 b t tf ;
or H = Hi
0 b t tf ;
1c
0xb t = 0:
1d
h
i
k
k
di t = s qi t ; for k = 0;
h
i
k
k
k k1
di t = s qi t + i di t ; for other k;
Solid region
Mushy region
Liquid region
!
TTsol
:
Tliq Tsol
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TE
kT = fs T ks + 1fs T kl :
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sqs ; ql =
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t
2
0f Tsol T xs ; t; qs ; ql dt
t
0f
h
i2
Tliq T xl ; t; qs ; ql dt: 5
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EC
RR
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CO
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h
i
k + 1
t b ;
s q
UN
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n h
i
h
io h
i
t
0f s qki t s qk1
t s qki t dt
i
n
:
=
2 o
t
dt
t
0f s qk1
i
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0i = 0
ki
fs = 1
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TbTsol
Tsol TTliq
T N Tliq
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where k denotes the iteration number. The iteration is started by using 185
186
q0i (t) = 0. The direction of descent dki (t) is updated from the following 187
formula:
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k k
t = qi t i di t ; i = s; l; t N 0
1b
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T = Ti
k + 1
qi
= ql t x = b
x=b
For the computation of the unknown heat uxes qs(t) and ql(t) by 182
the conjugate gradient method, the following general iteration 183
process is performed.
184
1a
x = 0 0 b t tf ;
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C T T
2
= 2 kT T
t
x
kT
x
kT
x
0bxbb
0 b t tf ;
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10a
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x=0
= qs t x = 0 0 b t tf ;
10b
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x=b
= ql t x = b
0 b t tf ;
10c
T = 0 0 x b t = 0 :
10d
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f
C T = fs cs + 1fs cl + s cs Tcl TSte
>
T
>
>
:
cl
TbTsol
Solid region
Tsol TTliq
Mushy region
T N Tliq
Liquid region
Please cite this article as: A. Abbas Nejad, et al., Int. Commun. Heat Mass Transf. (2010), doi:10.1016/j.icheatmasstransfer.2010.03.002
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13d
tf
tf
k
k
k
k
F2 = Txs Tsol Tl;xs dt + Txl Tliq Tl;xl dt;
0
13e
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0f 10 x; t k
T
H
dxdt:
t
x2
i2
Tliq T xl ; t; qs ; ql dt +
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In this section, rst we introduce the method used for the solution
of direct problem for the validation purpose with some other
numerical simulations. Then the performance of the proposed inverse
approach is investigated by the solution of the inverse control
problem for a pure material which has one moving interface between
solid and liquid phases. The obtained solution is compared with
previous analytical [21] and numerical [3,16] solutions. Then, the
problem involving alloy solidication with two moving boundaries is
considered. The obtained solution is validated by comparing the
desired and computed front positions due to the lack of any other
numerical and experimental studies for controlling solidus and
liquidus front positions or mushy zone thickness.
The compact third order Runge Kutta along with central nite
difference method is applied to solve the direct, sensitivity and adjoint
equations. Temporal and spatial grid dimensions are assigned
according to the front velocities. Detailed discussion about the
approach and the results can be found in Abbas Nejad et al. [22].
To evaluate the performance of the direct solver, the solution of
direct PbSn alloy solidication problem with known boundary
conditions is compared with an existing numerical approach [23].
The comparison of the temperature history at x = 0.37 in Fig. 2 and the
solidus and liquidus front positions are illustrated in Fig. 3.
A special case of pure material solidication with constant velocity
at the interface with Ti = Tf = 0, Ste = 0.5 is considered to study the
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x; t
x; t
+ kT
C T
+ 2fTTsol xxs +
t
x2
0bxbb
h
i
TTliq xxl g = 0
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249
18b
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RR
"
t
0f
18a
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t
2
0f Tsol T xs ; t; qs ; ql dt
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tf
tf
k
k
k
k
F1 = Txs Tsol Ts;xs dt + Txl Tliq Ts;xl dt;
sqs ; ql =
sqs t = 0; t ;
13c
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sql t = b; t :
tf
sq = 0f qsqt dt:
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Comparing the last two equations yields to the expressions for 262
calculation of the boundary heat ux gradients:
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tf
tf
2
2
k
k
A22 = Tl;xs dt + Tl;xl dt;
tf
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13a
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where, is the Dirac delta function. After eliminating the terms 255
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consisting T(x, t), only the following integral term is left.
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15d
where
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t = tf ; 253
sqs ; ql = 0f 0; t qs dt + 0f b; t ql dt:
tf
tf
2
2
k
k
A11 = Ts;xs dt + Ts;xl dt;
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0xb
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=0
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A. Abbas Nejad et al. / International Communications in Heat and Mass Transfer xxx (2010) xxxxxx
0bttf ;
15a
=0
x
x = 0 0bttf ;
=0
x
x = b 0bttf
15b
15c
Please cite this article as: A. Abbas Nejad, et al., Int. Commun. Heat Mass Transf. (2010), doi:10.1016/j.icheatmasstransfer.2010.03.002
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A. Abbas Nejad et al. / International Communications in Heat and Mass Transfer xxx (2010) xxxxxx
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V t
q0; t = 0:5 Ve
RO
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Fig. 5. A. Desired and computed front positions for Vl = 2, Vs = 1.25. B. Desired and
computed front positions for constant mushy zone thickness.
EC
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RR
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CO
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UN
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Please cite this article as: A. Abbas Nejad, et al., Int. Commun. Heat Mass Transf. (2010), doi:10.1016/j.icheatmasstransfer.2010.03.002
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error =
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xdesired xcomputed
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xdesired
20
1 = M M
m = 1 xdesired;m xcomputed;m
r
1 = MM
m = 1 xdesired;m
21
100;
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5. Conclusion
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t1:1
t1:2
t1:3
t1:4
t1:5
t1:6
t1:7
EC
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RR
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384
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where, M is the total number of time steps and x is the solidus or the
liquidus front position. The values of RMS error for solidus and
liquidus positions, the number of iterations needed for minimizing the
objective function and the objective function value for the last
iteration are listed in Table 1.
Table 1 indicates that the present approach has a very good
convergence and accuracy in all cases. Also, it can be observed that the
solution exhibits a better convergence for the thick mushy zones with
two moving sensors far from each other.
From the obtained results, it can be observed that the desired
mushy zone thickness which leads to a desired product quality is
achieved.
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References
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A. Abbas Nejad et al. / International Communications in Heat and Mass Transfer xxx (2010) xxxxxx
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Table 1
Comparison of the objective function and RMS error for different mushy zone
thicknesses.
Solidus
velocity
Liquidus
velocity
Objective
function
Iteration
numbers
Solidus
eRMS%
Liquidus
eRMS%
0.25
1.25
1.75
2
2
2
2
2
3.1e4
4.078e4
8.33e4
3.69e4
25
41
64
70
7.23
4.25
6.43
5.86
4.72
5.63
7.15
4.70
Please cite this article as: A. Abbas Nejad, et al., Int. Commun. Heat Mass Transf. (2010), doi:10.1016/j.icheatmasstransfer.2010.03.002