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