Mechanical Engineering

Indian Institute of Technology Kanpur

ME669A

ME669A
MODELLING THERMAL TRANSPORT IN MANUFACTURING PROCESSES
Credits:
 3009
Pre-requisite: 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, Two-phase 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 solid-liquid and/ or liquid-vapour 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.
Lecturewise Breakup
Topic No. of hours  
1. Review of fundamentals of thermal transport in manufacturing
  1. Introduction to the course - Importance of heat transfer in manufacturing and applications
  2. Steady and transient heat conduction, Convection and Radiation, Natural convection
  3. Fluid flow and Mass transfer
 01
02
02
2. Finite Difference and Finite Volume based modelling of heat transfer in manufacturing and numerical implementation
  1. Basic introduction to FDM and FVM techniques, Mathematical formulation of thermal transport, Governing equations and general scalar transport equation
  2. Steady and unsteady problems, Initial and Boundary conditions, Convection-diffusion problems
  3. Mesh terminology, Accuracy, Consistency, Stability and Convergence
  4. Phase change - Enthalpy based algorithm for Melting/solidification, Two-phase mushy zone flows, Liquid- vapour phase change involved in manufacturing
  5. Illustration using code
 02
02
01
02
02
3. Case studies on modelling of thermal transport in manufacturing processes
  1. Solidification processing – Modelling of moving melting/solidification phase change interface, Alloy solidification, Segregation, Two-phase mushy zone flow, Modelling of casting, Marangoni convection driven flow, Modelling of welding
  2. Heat assisted manufacturing process – Thermal modelling using enthalpy method for solid-liquid and/ or liquid-vapour 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
  3. Thermal deposition process – Modelling of free surface evolution, Modelling of droplet impact and deposition on substrates
 08
14
04
  Total 40
References
  1. R.N.Smith, C.H Doumanidis, R. Pitchumani, Chapter 17, Heat Transfer in Manufacturing and Materials Processing, John Wiley & Sons Inc., 2006.
  2. 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.
  3. S.V. Patankar, Numerical Heat Transfer and Fluid Flow, McGraw-Hill, New York, 1980.
  4. J. Dowden (Ed.), The Theory of Laser Materials Processing in Heat and Mass Transfer in Modern Technology, Springer, 2008.
  5. D.M. Stefanescu Science and Engineering of Casting Solidification, 2nd ed., Springer, 2008.
  6. M.P. Groover, Fundamentals of Modern Manufacturing, John Wiley & Sons Inc., 2010.
  7. Larry F. Jeffus, Welding: Principles and Applications, 4th ed., Thomson Learning, 1999.
  8. L. Pawlowski, The Science and Engineering of Thermal Spray Coatings, 2nd ed., John Wiley & Sons Inc, 2008.