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Abstract
In this paper, a meshless method, finite point method, is studied and applied to model metal solidification processes in continuous casting. An
additional term is added to stabilize the computation with Neumann boundary. The enthalpy method is used to calculate the latent heat and the
corresponding iterative solution is given. An iteration scheme for nonlinear material calculation is also constructed. The model is verified by the
classical Stefan problem and a 2D FEM solidification example. And then it is applied to the simulation of the solid shell growth in the continuous
casting of a large square bland in mold. The result is coincided with the measurement.
© 2007 Elsevier B.V. All rights reserved.
Keywords: Meshless method; Finite point method; Solidification; Stefan problem; Continuous casting
0924-0136/$ – see front matter © 2007 Elsevier B.V. All rights reserved.
doi:10.1016/j.jmatprotec.2007.04.092
Author's personal copy
512 L. Zhang et al. / Journal of Materials Processing Technology 192–193 (2007) 511–517
Finite point method was proposed by Onate et al. [11,12]. For The energy equilibrium equation and boundary conditions of
a typical boundary value problem, the weighted residual method solidification processes are [3].
and the idea of point collocation are used with the unknown func- Equilibrium equation:
tion replaced by the moving least-square (MLS) approximation.
Then the FPM collocation form of the differential equations can ∂T
ρcp − k∇ 2 T − qv = 0 (4a)
be obtained. ∂t
Author's personal copy
L. Zhang et al. / Journal of Materials Processing Technology 192–193 (2007) 511–517 513
Heat flux boundary condition: where θ is constant between 0 and 1, representing different
discretization form [15]:
∂T ⎧
−k + qn = 0 (4b)
∂n ⎪
⎨ 0, implicit
θ = 0.5, Crank–Nicolson (9)
Initial condition: ⎪
⎩
1, explicit
T |t=0 = Tin (4c)
3.5. Latent heat treatment
where T is the temperature (K), t the time (s), cp the specific
heat (J/kg K), ρ the density (kg/m3 ), k the thermal conductivity In Eq. (4a), if setting qv equal to zero, and importing enthalpy
(W/m K), qv the energy source term (W/m3 ), n the normal to the [16], the energy equilibrium becomes
boundary, qn the known heat flux at the boundaries (W/m2 ) and
Tin is the initial temperature (K). ∂h ∂T
k∇ 2 T = ρ (10)
∂T ∂t
3.2. Neumann boundary stabilization scheme where h is enthalpy.
Replacing ∂h/∂T with its difference form and ∂T/∂t with its
For solving convection and diffusion problems by FPM, Neu- implicit form of discretization in time, Eq. (10) becomes:
mann boundary needs to be stabilized first. For non-selfadjoint
∼
T̃i t+t − Ti |t
problems such as convection-diffusion problems, the domina- h T̃i t+Δt − h T̃i t
tion of convection item will lead to unstable problems. So a ρ · − ri |t+t
special treatment is needed to stabilize the solution by applying T t
the standard conservation laws expressing balance of momen- =0 (11)
tum and mass over a control domain. The related works can be
where ri |t+t = k∇ 2 T̃i t+t .
seen in Onate’s papers [11,12], and a stabilization item is added
Eq. (11) cannot be solved directly, so the corresponding iter-
to Neumann boundary:
ative solution is given as
∂T h
−k + qn − r = 0
m+1
∂n 2
(5)
h T̃i i − h ( Ti |t ) T̃i t+t − T̃i t
ρ · − ri |m+1
t+t = 0
T t
where r = k2 T + qv and h is the characteristic length [11,12].
(12)
m+1
3.3. Discretization in space where ri |t+t = k∇ 2 T̃i t+t , and m is the number of iteration.
m+1
By using MLS [13], the approximation function of the 3.6. Nonlinear material treatment
unknown temperature T of node i at time t can be expressed
as If the material properties are functions of temperature, the
energy equilibrium equation for a solidification process can be
n
expressed as
Ti |t ≈ Tih = ψI · TI |t (6)
t
I ∂h ∂T
k(T )∇ 2 T = ρ(T ) (13)
Then the derivatives of T with respect to space become the ∂T ∂t
derivatives of the shape function ψ with respect to space: Same as Eq. (11), replacing ∂h/∂T and ∂T/∂t, and setting k and
ρ the function of the present temperature at time t + t, then
n
∇ 2 t T̃ |t =
∇ 2 ψI T h .
h T̃i t+t − h T̃i t T̃i t+t − T̃i t
(7a)
t
I ρ Ti |t+t · ·
T t
∂ T̃ t n
∂ψI
− ri |t+t = 0 (14)
= · TIh (7b)
∂n ∂n t
I
where ri |t+t = k T̃i t+t · ∇ 2 T̃i t+t .Eq. (14) cannot be
3.4. Discretization in time solved directly either. The corresponding iterative solution is
m
h T̃i m t+t
− h T̃
i t T̃
i t+t − T̃
i t
m
General two point difference format of T with respect to time ρ T̃i t+t · ·
t [14] is substituted into the energy equilibrium Eq. (4a), then it T t
becomes: − ri |m+1
t+t = 0 (15)
T̃i t+t − T̃i t
m
m+1
ρcp − θ · ri |t+t − (1 − θ) · ri |t = 0 (8) where ri |m+1
t+t = k T̃i t+t · ∇ 2 T̃i t+t .
t
Author's personal copy
514 L. Zhang et al. / Journal of Materials Processing Technology 192–193 (2007) 511–517
4. Verifications
4.1. 1D case
Table 1
Material properties [18]
Parameters Value
L. Zhang et al. / Journal of Materials Processing Technology 192–193 (2007) 511–517 515
Fig. 7. Solid front locations calculated with FPM in comparison to FEM results. (a) Geometry model; (b) photograph of mold.
Fig. 8. Continuous casting of large bland. (a) Geometry model; (b) discretization
model (quarter). Fig. 9. Continuous casting large bland mold.
Author's personal copy
516 L. Zhang et al. / Journal of Materials Processing Technology 192–193 (2007) 511–517
5. Application
6. Summary
L. Zhang et al. / Journal of Materials Processing Technology 192–193 (2007) 511–517 517
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