ME669A - Modeling Thermal Transport in Manufacturing Processes

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.

2. Finite Difference and Finite Volume based modeling 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-vapor phase change involved in manufacturing,
5. Illustration using code.

3. Case studies on modeling of thermal transport in manufacturing processes:

1. Solidification processing – Modeling of moving melting/solidification phase change interface, Alloy solidification, Segregation, Two-phase mushy zone flow, Modeling of casting, Marangoni convection driven flow, Modeling of welding,
2. Heat assisted manufacturing process – Thermal modeling using enthalpy method for solid –liquid and/ or liquid-vapor phase change interface. Melt pool formation and flow behavior, Beam heat flux models, Example problems of thermal modeling in Laser Melting (LM), Electron Beam Melting(EBM), Machining: Electric Discharge Machining (EDM) and Heat assisted micro manufacturing process,
3. Thermal deposition process – Modeling of free surface evolution, Modeling of droplet impact and deposition on substrates.