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Workshop (Appendix) Phase Change

ANSYS Mechanical Heat Transfer

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Workshop (Appendix) - Phase Change

Problem Description

Training Manual

The model represents cooling of molten aluminum contained in a sand cast for a wheel.
The aluminum has a melting point of 696 C.

To economize the analysis will be conducted using a 2D axisymmetry model of the wheel and mold.

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Workshop (Appendix) - Phase Change

Problem Description

Training Manual

Since this is a phase change problem well need to include enthalpy as a material property. To do this we need to use a command object. The basic properties are shown below. Later in the workshop we will use this data to construct a table representing enthalpy versus temperature. Aluminum Alloy:
Density = 2770 kg/m3 Specific Heat (solid) = 876 J/(kg* C) Specific Heat (liquid) = 1050 J/(kg* C) Melting Temperature = 696 C Transition Temperature = 695 C Liquid Temperature = 697 C Latent Heat = 395440 J/kg

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Workshop (Appendix) - Phase Change

Units Setup

Training Manual

Open Workbench and specify the unit system Metric (kg, m, s, C, A, N, V). Choose to Display Values in Project Units.

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Workshop (Appendix) - Phase Change

Model Setup
1. From the Workbench project page toolbox, select a Transient Thermal analysis system. 2. Double click the Engineering Data.

Training Manual

3. Highlight the Engineering Data cell and enter Sand as a new material.

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Workshop (Appendix) - Phase Change

Model Setup
4. From the Toolbox drag and drop Density, Isotropic Thermal Conductivity and Specific Heat onto the Sand property. 5. Enter the property values:
Density = 1520 kg/m3 Conductivity = 0.346 W/(m* C) Specific Heat = 816 J/(kg* C)

Training Manual

6. Highlight the General Materials library. 7. Click the + next to Aluminum Alloy to add it to the project.

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Workshop (Appendix) - Phase Change

Model Setup
8. Highlight Engineering Data in the Outline filter. 9. Highlight Aluminum Alloy 10. Highlight, RMB and delete the properties Density and Specific Heat.
Note, for phase change problems, the property enthalpy is used which is defined in terms of density and specific heat. Since this property is not supported in the engineering data application we need to add a command object to define it. We delete density and specific heat here so as not to overwrite the enthalpy definition.

Training Manual

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Workshop (Appendix) - Phase Change

Model Setup
11. Using the properties shown in the table, enter new data for the aluminum alloy thermal conductivity.

Training Manual

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Workshop (Appendix) - Phase Change

Model Setup
12. Return to the project schematic. 13. Highlight the Geometry cell, RMB > Properties.

Training Manual

14. In the Advanced Geometry Options set the Analysis Type to 2D.

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Workshop (Appendix) - Phase Change

Model Setup
15. Right click the Geometry cell and import geometry Sand_Casting_WSA1.x_t.

Training Manual

16. Double click the Model cell to open the Mechanical application.

17. Highlight the Geometry branch and set the 2D Behavior to Axisymmetric .

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Workshop (Appendix) - Phase Change

Model Setup
18. Highlight the part, Mold and assign the material Sand.

Training Manual

19. Highlight the part, Wheel and assign the material Aluminum Alloy.
A warning message will be issued (see below), since we deleted density and specific heat. We will be adding enthalpy so we can ignore the warning.

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Workshop (Appendix) - Phase Change

Model Setup
20. Highlight the Wheel part, RMB > Insert Commands.

Training Manual

21. Using the aluminum properties shown earlier and the equations on 7-19 we calculate enthalpy as a function of temperature E(T) as:
E(0) = 0 E(695) = 1.6857e9 E(697) = 2.7614e9 E(1000) = 3.6626e9

22. Enter the mptemp and mpdata commands as shown in the command window:

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Workshop (Appendix) - Phase Change

Solution Setup
23. Highlight Initial Temperature and set to 30 C.

Training Manual

24. Highlight Analysis Settings and set auto time stepping as shown below.
This will be a 2 step solution.

The first step has a duration of 0.01s where the initial temperature load for the aluminum will be applied. In the second step (25 minutes or 1500 seconds) the temperature load will be removed and the aluminum allowed to cool to solidification. See details on next slide.
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Workshop (Appendix) - Phase Change

Solution Setup
Step 1:
Auto Time Stepping = On End time = 0.1 s Initial time step = 1e-3 s Minimum time step = 1e-3 s Maximum time step = 0.1 s

Training Manual

Step 2:
Auto Time Stepping = On End time = 1500 s Initial time step = 1e-3 s Minimum time step = 1e-4 s Maximum time step = 5 s

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Boundary Conditions
25. Highlight the Transient Thermal branch. 26. Select the top line on the mold and RMB > Insert > Convection. Details:
Film Coefficient = 5.75 W/(m2* C) Ambient Temperature = 30 C

Training Manual

27. Select the right side line on the mold and RMB > Insert > Convection. Details:
Film Coefficient = 7.5 W/(m2* C) Ambient Temperature = 30 C

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Workshop (Appendix) - Phase Change

Boundary Conditions
28. Change the selection filter to body select and select the Wheel part. 29. RMB > Insert > Temperature. 30. In the details change magnitude to Tabular Data. 31. In the table enter 800 C for time = 0.1s (note this will automatically fill the temperature for time = 1500s as well). 32. RMB step 2 (t = 1500s) and Activate/Deactivate at this step!
Note, deactivating the temperature at this point removes the temperature load during the second step. This is NOT the same as setting the temperature to zero.

Training Manual

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Workshop (Appendix) - Phase Change

Solution and Results


33. Solve the model.

Training Manual

Note depending on hardware, the solution could take 15 minutes.

When the solution is complete insert temperature results for the entire model to review.

Recall from the model setup that the melting temperature of the aluminum is 696 C. A 3 color legend can be setup to show solidification over time
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Workshop (Appendix) - Phase Change

Solution and Results

Training Manual

A plot of the global maximum temperature shows a relatively flat cooling profile in the aluminums transition region (695 697 C). Once solidification is complete the cooling proceeds at an increased rate.
Transition Region

696 C

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Workshop (Appendix) - Phase Change

Solution and Results

Training Manual

By locating coordinate systems at desired locations and attaching temperature probes to the wheel, a chart can be constructed showing temperature over time at each location.

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