ME669A

MODELLING THERMAL TRANSPORT IN MANUFACTURING PROCESSES



Prerequisites: None
Review of fundamentals of thermal transport in manufacturing: Introduction to the course, Steady and transient heat conduction, Convection and Radiation, Natural convection. Finite Volume based modelling of heat transfer in manufacturing and numerical implementation, Phase change  Enthalpy based algorithm for Melting/solidification, Twophase mushy zone flows, Liquid vapour phase change involved in manufacturing, Illustration using code. Case studies on modelling of thermal transport in manufacturing processes: Solidification processing – Casting, Marangoni convection driven flow, Arc, Laser/Electron beam welding. Heat assisted manufacturing process – Thermal modelling using enthalpy method for solidliquid and/ or liquidvapour phase change interface, Melt pool formation and flow behaviour, Beam heat flux models, Laser/ Electron beam melting, Electric discharge machining. Thermal deposition process – Modelling of free surface evolution, Modelling of droplet impact and deposition on substrates.
Lcturewise breakup:

Topic

No. of hours

1. Review of fundamentals of thermal transport in manufacturing


Introduction to the course  Importance of heat transfer in manufacturing and applications

Steady and transient heat conduction, Convection and Radiation, Natural convection

Fluid flow and Mass transfer

01 02 02

2. Finite Difference and Finite Volume based modelling of heat transfer in manufacturing and numerical implementation


Basic introduction to FDM and FVM techniques, Mathematical formulation of thermal transport, Governing equations and general scalar transport equation

Steady and unsteady problems, Initial and Boundary conditions, Convectiondiffusion problems

Mesh terminology, Accuracy, Consistency, Stability and Convergence

Phase change  Enthalpy based algorithm for Melting/solidification, Twophase mushy zone flows, Liquid vapour phase change involved in manufacturing

Illustration using code

02 02 01 02 02

3. Case studies on modelling of thermal transport in manufacturing processes


Solidification processing – Modelling of moving melting/solidification phase change interface, Alloy solidification, Segregation, Twophase mushy zone flow, Modelling of casting, Marangoni convection driven flow, Modelling of welding

Heat assisted manufacturing process – Thermal modelling using enthalpy method for solidliquid and/ or liquidvapour phase change interface, Melt pool formation and flow behaviour, Beam heat flux models, Example problems of thermal modelling in Laser Melting (LM), Electron Beam Melting (EBM), Machining: Electric Discharge Machining (EDM) and Heat assisted micro manufacturing process

Thermal deposition process – Modelling of free surface evolution, Modelling of droplet impact and deposition on substrates

08 14 04


Total

40

Reference Texts:

R.N.Smith, C.H Doumanidis, R. Pitchumani, Chapter 17, Heat Transfer in Manufacturing and Materials Processing, John Wiley & Sons Inc., 2006.

T.L. Bergman, A.S. Lavine, F.P. Incropera, D.P. DeWitt, Fundamentals of Heat and Mass Transfer, 6th Edition, Wiley India Pvt. Ltd., 2006.

S.V. Patankar, Numerical Heat Transfer and Fluid Flow, McGrawHill, New York, 1980.

J. Dowden (Ed.), The Theory of Laser Materials Processing in Heat and Mass Transfer in Modern Technology, Springer, 2008.

D.M. Stefanescu Science and Engineering of Casting Solidification, 2nd ed., Springer, 2008.

M.P. Groover, Fundamentals of Modern Manufacturing, John Wiley & Sons Inc., 2010.

Larry F. Jeffus, Welding: Principles and Applications, 4th ed., Thomson Learning, 1999.

L. Pawlowski, The Science and Engineering of Thermal Spray Coatings, 2nd ed., John Wiley & Sons Inc, 2008.
