652-2307/01 – Basics of manufacturing process simulation (ZSVP)
| Gurantor department | Department of Metallurgical Technologies | Credits | 5 |
| Subject guarantor | Ing. Petr Opěla, Ph.D. | Subject version guarantor | Ing. Petr Opěla, Ph.D. |
| Study level | undergraduate or graduate | Requirement | Compulsory |
| Year | 3 | Semester | summer |
| | Study language | English |
| Year of introduction | 2023/2024 | Year of cancellation | |
| Intended for the faculties | FMT | Intended for study types | Bachelor |
Subject aims expressed by acquired skills and competences
- Student will be able to explain the essence of the finite element method.
- Student will be able to prepare the simulations of basic metallurgical processes.
- Student will be able to prepare the simulations of basic foundry processes.
- Student will be able to prepare the simulations of basic forming processes.
Teaching methods
Lectures
Tutorials
Summary
The course introduces students to the issue of metallurgical, foundry and forming process simulations in a clear way, and practically introduces students to the phase of the simulation preparing (preprocessing).
Compulsory literature:
Recommended literature:
Way of continuous check of knowledge in the course of semester
Credit: active participation in tutorials.
Exam: a written test.
E-learning
FABÍK, R. Modelling of Forming Processes. Electronic study aid. Available from: https://www.vsb.cz/e-vyuka/en. Ostrava, 2013. 74 p.
Other requirements
Attendance at least 75%. Get min. 21 points out of 30 for tutorials and min. 35 points out of 70 for exam.
Prerequisities
Subject has no prerequisities.
Co-requisities
Subject has no co-requisities.
Subject syllabus:
Lectures:
1) The principle of numerical modelling of metallurgical processes. Overview of available simulation software.
2) The project preparation in the ANSYS Workbench (integrated environment editor).
3) The principle of physical modelling of metallurgical processes. Similarity of systems, constants of similarity. Dimensionless parameters (similarity criterions), distribution and properties of similarity criterions.
4) Basic use of computer technology for simulation of casting and solidification of castings.
5) Preparation and processing of a virtual model including design of the gating system (GS), technological allowances and mould design.
6) Data processing and evaluation of results in the Magma simulation software.
7) Basic physical quantities coupled with the hot forming processes (temperature, strain, strain rate, flow stress), their mutual relationships and the possibilities of an analytical determination of their course inside a formed workpiece.
8) Finite Element Method (FEM) for the numerical determination of the metal flow course inside a formed workpiece.
9) The assembling of the virtual models of forming tools and workpiece by means of a Computer-Aided Design (CAD) software and dealing with a simulation software.
10) Summary or the addition of basic knowledge.
Tutorials:
1) The principle of numerical modelling of metallurgical processes with CFD program ANSYS Fluent. Software Design modeler – geometry of modelling and software Mesh – creation of computational mesh.
2) Processing – solving and postprocessing in software ANSYS Fluent.
3) Visit to the Laboratory of physical modelling, a dynamic demonstration of the physical model of the ladle, the physical model of the refining ladle and the physical model of the five-strands tundish of continuous casting of steel.
4) Creation and processing of the virtual model including the design of the gating system (GS).
5) Definition and specification of initial and boundary conditions in the design of prototype and production processes.
6) Check of the designed casting geometry and GS. Identification and prediction of potential defects, elimination of casting hot spots and volume changes.
7) The simulation of an upsetting process.
8) The simulation of a cogging process.
9) The simulation of a flat rolling process.
10) Summary or the addition of basic knowledge.
Conditions for subject completion
Occurrence in study plans
Occurrence in special blocks
Assessment of instruction
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