Numerical and Experimental Investigation of the Melt Casting of Explosives

Sun, Da‐Wen; Garimella, Suresh V.; Singh, Sanjeev Kumar; Naik, Neelam

doi:10.1002/prep.200500028

Cited by 27 publications

(14 citation statements)

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“…(4), (8), (9), are solved using the commercial software package FLUENT, with the SIMPLEC algorithm employed for pressure-velocity coupling, the pressure staggered option (PRESTO!) used for pressure correction, and the volume-of-fluid (VOF) method employed for the free surface.…”

Section: Mathematical Modelingmentioning

confidence: 99%

“…Numerical investigations of solidification heat transfer have focused on the analysis of heat conduction and melt convection; the effects of shrinkage have often been ignored due to the difficulties involved in multiphase pressure-velocity coupling, and the interaction between free surface dynamics and solidification volume change [6][7][8]. The effects of density change on solidification can be studied by using continuous mass feeding to avoid the difficulties of tracking the shrinkage shapes explicitly [9,10].…”

Section: Introductionmentioning

confidence: 99%

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Numerical and Experimental Investigation of Solidification Shrinkage

Sun

Garimella

2007

Numerical Heat Transfer, Part A: Applications

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The solidification heat transfer, melt convection and volume shrinkage in the casting of an energetic material are analyzed through numerical modeling and experimental investigation. The shrinkage resulting from phase change is considered through the volume of fluid method. The model is validated against an analytical solution and then applied to study the volume contraction during the casting of tri-nitro-toluene (TNT). Good agreement is obtained between experimental results and predictions of temperatures at selected locations as well as shrinkage shape. New casting conditions are suggested based on the analysis, and improved results are observed both numerically and experimentally.

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Section: Mathematical Modelingmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Numerical and Experimental Investigation of Solidification Shrinkage

Sun

Garimella

2007

Numerical Heat Transfer, Part A: Applications

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Section: Introductionmentioning

confidence: 99%

“…The effects of natural convection in the melt induced by solidification are relatively well understood. Extensive analytical, experimental and numerical efforts have been reported on this topic [1][2][3][4][5][6].Thermal stresses induced during the casting process are, in general, less well understood. Analytical solutions have been suggested under simpler conditions and geometries such as high-pressure die casting [7].…”

mentioning

confidence: 99%

“…A butt curl mechanism was proposed for sheet ingots (with a width to thickness ratio of 3) based on bending due to differential expansion [15]. Using finite volume and finite element methods, a preliminary study of both solidification heat transfer and residual stress during casting of high Prandtl number fluids was carried out by Sun et al [4,23]. The effect of changing the cooling conditions on the resulting stresses was investigated.…”

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confidence: 99%

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Analysis and Suppression of Base Separation in the Casting of a Cylindrical Ingot

Annapragada

Sun

Garimella

2008

Heat Transfer Engineering

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This paper presents a comprehensive numerical investigation of the influence of cooling conditions on base separation, void formation and thermally induced stresses during the solidification of a high INTRODUCTIONCasting is an established and widely used process for manufacturing complex shapes without the necessity of applying large forces. It is especially useful in processing energetic materials which cannot tolerate high forces. The ambient cooling conditions play an important role in determining the quality of the final cast product. One measure of quality is the nearness of the product to the final shape desired with little or no residual stresses. An example of deviation from the desired shape is base separation [1]. Well-designed cooling conditions could help avoid such deleterious effects.In casting processes, the heat transfer, fluid flow, and phase change processes and the induced stresses are strongly coupled. The effects of natural convection in the melt induced by solidification are relatively well understood. Extensive analytical, experimental and numerical efforts have been reported on this topic [1][2][3][4][5][6].Thermal stresses induced during the casting process are, in general, less well understood. Analytical solutions have been suggested under simpler conditions and geometries such as high-pressure die casting [7]. It is also challenging to experimentally visualize thermal stresses. Interesting approaches such as the use of X-ray diffraction [8] and neutron diffraction [9] have been suggested. However, these approaches require high-intensity emitters and can be prohibitively expensive. Moreover, transient development of the three-dimensional stress field is very difficult to map. Numerical simulation of thermal stresses also poses several challenges. The stress analysis must consider dynamic coupling between solidification heat transfer and the resulting stresses induced in order to predict the developing gap between mold and cast product. The governing equations for thermal transport and stress should be coupled to model the transient development of thermal stresses. 3Finite element methods (FEM) have been widely used to numerically simulate casting problems. Thomas [10] reviewed in detail the various FEM thermal stress models and discussed difficulties in practical implementation. Contact conductance between the casting and the mold was modeled by Fackeldey et al. [11] as a simple function of pressure. But the separation of the casting from the mold, which has a detrimental effect on heat transfer, was neglected. Several models have been proposed to address this separation. Seetharamu et al. [12] considered loss of contact between the mold and the cast, and modeled the heat transfer as being across an air gap. Isaac et al. [13] predicted the size and distribution of the separation and modeled it as gap conductance.Accurate materials characterization is also important for modeling thermal stresses as, in general, materials change from viscoelastic/viscoplastic in the liquid phase to el...

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Computational Multi‐Phase Modeling of Cast Energetic Materials

Mudryy

Nastac

2013

EPD Congress 2013

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Numerical and Experimental Investigation of the Melt Casting of Explosives

Cited by 27 publications

References 13 publications

Numerical and Experimental Investigation of Solidification Shrinkage

Numerical and Experimental Investigation of Solidification Shrinkage

Analysis and Suppression of Base Separation in the Casting of a Cylindrical Ingot

Computational Multi‐Phase Modeling of Cast Energetic Materials

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