Abstract
This thesis is based on 34 scientific articles published in international journals during the period 1998 to 2021. They all one way or the other cover the topic of how to mathematically model the fundamental multiphysical phenomena which take place during manufacturing processes.
All models involve elements from the three generic pillars of numerical heat transfer, computational fluid dynamics as well as computational solid mechanics for the following manufacturing processes: Metal casting, spray forming, friction stir welding, tape casting, pultrusion as well as additive manufacturing.
PAPERS 1-4 present two types of models for metal casting where the first adresses automatic optimization of certain defects in a steel forging ram and the second deals with the micromechanics of ductile cast iron.
PAPERS 4-9 present models for spray forming including droplet atomization and deposition and combine them together in a coupled, unified spray forming model which takes shadowing effects into account.
PAPERS 10-16 present models for friction stir welding in which the heat generation and the subsequent thermal fields are calculated together with more advanced models accounting for material flow based on both fluid mechanical as well as solid mechanical formulations.
PAPERS 17-20 present models for tape casting in which the flow in the doctor blade region as well as the side flow is analyzed by analytical methods and the subsequent drying is described by a simple diffusion model.
PAPERS 21-27 present models for pultrusion including thermal models of both transient and steady state nature as well as thermo-mechanical models based on 2D plane strain, 2D generalized plane strain as well as full 3D.
PAPERS 28-34 present models for metal additive manufacturing including pure conductive models, thermo-fluid models as well as thermo-mechanical models for both laser powder bed fusion (L-PBF) and direct energy deposition (DED).
All models involve elements from the three generic pillars of numerical heat transfer, computational fluid dynamics as well as computational solid mechanics for the following manufacturing processes: Metal casting, spray forming, friction stir welding, tape casting, pultrusion as well as additive manufacturing.
PAPERS 1-4 present two types of models for metal casting where the first adresses automatic optimization of certain defects in a steel forging ram and the second deals with the micromechanics of ductile cast iron.
PAPERS 4-9 present models for spray forming including droplet atomization and deposition and combine them together in a coupled, unified spray forming model which takes shadowing effects into account.
PAPERS 10-16 present models for friction stir welding in which the heat generation and the subsequent thermal fields are calculated together with more advanced models accounting for material flow based on both fluid mechanical as well as solid mechanical formulations.
PAPERS 17-20 present models for tape casting in which the flow in the doctor blade region as well as the side flow is analyzed by analytical methods and the subsequent drying is described by a simple diffusion model.
PAPERS 21-27 present models for pultrusion including thermal models of both transient and steady state nature as well as thermo-mechanical models based on 2D plane strain, 2D generalized plane strain as well as full 3D.
PAPERS 28-34 present models for metal additive manufacturing including pure conductive models, thermo-fluid models as well as thermo-mechanical models for both laser powder bed fusion (L-PBF) and direct energy deposition (DED).
| Original language | English |
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| Place of Publication | Kgs. Lyngby |
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| Publisher | Technical University of Denmark |
| Number of pages | 179 |
| Publication status | Published - 2024 |