Laboratory work 3

" Non-stationary analysis of ingot solidification in two-dimensional

formulation "

1 Purpose of work

Learn to solve two-dimensional non-stationary thermal problems, taking into

account the temperature dependence of material properties and the heat transfer
coefficient.

2 Statement of the problem and assumptions made

A long ingot, the cross section of which is shown in the figure, after being
cast into a sand mold, cools down with it in air. The problem of non-stationary heat
conduction with conditions of the 3rd kind at the sand-air boundary is solved. The
cooling process is monitored for 10 minutes.

А steel

8
sand
4

4
4
4 14 4 Plane of
А symmetry

Figure 1 - Cross section of the model

Material properties:
.
Sand: thermal conductivity (KXX) – 0.35 W/(m*K); density (DENS) – 1600
kg/m3 ; heat capacity (C) – 850 J/(kg*K);
Steel:
T, K 273 780 1300 1480
KXX 15 18 31 34
C 450 550 620 640

Initial conditions: Steel T=1480 K; sand T=293.

1
 Heat transfer conditions: heat transfer coefficient at the sand-air boundary –
0.4 W/(m2*K); ambient temperature – 293 K.
Hypotheses: Due to the large length of the ingot in one direction, a flat
problem is solved. Due to the symmetry of the cross section (see Fig.), only half of
the area is considered. The properties of sand are constant, the thermal
conductivity and specific heat of the ingot material (steel) are temperature
dependent and are given in the form of a table. The change in specific heat reflects
the absorption of heat during solidification of the material.

3 Implementation of the task in command mode

Table 1 - The procedure for performing laboratory work in command mode

No Team Description Team

.
1. Set the title of the task; UM> File> Change title [ Slitok > OK]
Slitok -header
2. Enable Thermal Analysis MM> Preferences> [Thermal>OK]
Filter
(only items related to this
type of calculation will be
available in the main menu)
3. Choice of element type; MM>Preprocessor> Element
selected flat four-node four- Type>Add/Edit/Delete>Add>Thermal
sided element Mass>Solid- in Library of...[ 4 node 55>
OK]>Close
4. Setting properties for sand MM>Preprocessor>Material
(Material No. 1) props>Material
models>Thermal>Conductivity>Isotropic
[KXX=0.35>OK]

Specific Heat [C=850>OK]

Density [DENS=1600>OK]
5. Addition of material 2 ( steel MM>Preprocessor>Material
) props>Material models>Material>New
model> Enter number material 2>OK
6. Setting the tabular MM>Preprocessor>Material
dependence of the specific props>Material models> Select Material
thermal conductivity of steel Model Number
on temperature 2>Thermal>Conductivity>Isotropic
>Add temperature[temp1= 273,
2
 temp2=780,temp3=1300,temp4=1480,K
XX1=15,KXX2=18,
KXX3=31,KXX4=34>OK]
7. Setting the tabular MM>Preprocessor>Material
dependence of the specific props>Material models> Select Material
heat capacity of steel on Model Number 2>Thermal>>Specific
temperature Heat >Add temperature[temp1=273,
temp2=780,temp3=1300,temp4=1480,C1
=450,C2=550,C3 =620,C4=640>OK]
8. Displaying Material MM>Preprocessor>Material
Properties as a Graph props>Material Models>Material Model
(Thermal Conductivity) Number 2>Thermal Conduct. (iso) Graph
9. Displaying Material MM>Preprocessor>Material
Properties as a Graph props>Material Models>Material Model
(Specific Heat Capacity) Number 2> Specific Heat>Graph
10. Building points (vertices of MM>Preprocessor>Modeling>Create>
the sand model) Keypoints>In active CS

Enter in fields
[NTP=1,X,Y,Z=0,0,0>Apply]
[NTP=2,X,Y,Z=0.22,0,0>Apply]
[NTP=3,X,Y,Z=0.1 ,0.12,0>Apply]
[NTP=4,X,Y,Z=0,0.12,0>OK]
11. Enable point numbering UM>Plot controls>Numbering
Check the box [KP Keypoint
number>OK] field

enable region numbering Check the box [ AREA area number >
OK ]
12. Moving the origin symbol to UM>Plot Ctrls>Window controls>
the upper left corner of the Window Options[/Triad=At top left>OK]
graphics window:
13. Create a surface by points: MM > Preprocessor > Modeling > Create
> Areas > Arbitrary > Through KPs
[Mouse pointer to KPs 1 to 4 > OK ]
14. Saving a file UM>File>Save as>[Link]>OK
15. Create an area for steel MM>Preprocessor>Modeling>Create>Ar
ea>Rectangle>By dimensions

Enter [ X1=0.04, X2=0.22, Y1=0.04,

Y2=0.08> OK ]
16. Perform "Overlap" areas MM>Preprocessor>Modeling>Operate>
(overlap). This operation Booleans>Overlap>Areas[ Press pick all]
3
 separates the intersecting
parts of existing regions.
17. Removal extra area . MM>Preprocessor>Modeling>Delete>Ar
eas&Below[ Mark square A 3> OK]
18. We split the structure into MM>Preprocessor>Meshing>Size
elements with a given size of Ctrls>Manual size>Global>Size>[ Mark
the side of the element in the line Size=0.015> OK]

19. Divide into elements the area MM>Preprocessor

occupied by sand >Meshing>Mesh>Areas>free [ Check
A5>OK]
In this case, this area will be
assigned the properties of
material No. 1 by default.
20. We define the machine that MM>Preprocessor >Meshing>Mesh
all the following actions Attributes>Default attributes [ Enter in
when splitting will be for Mat 2]>OK
material No. 2
21. Display Surfaces UM > Plot > Areas
22. Breakdown into elements of MM>Preprocessor>Meshing>Mesh>Area
the area occupied by steel s>free [Check A4]>OK

23. Highlight different materials UM>Plot controls>Numbering [ In

with different colors Elements & Attributes numbers select
Material numbers,
In [/NUM] select Colors only]>OK
24. Saving a file MM>File>Save as [Link]
25. Selecting a non-stationary MM>Solution>Analysis Type>New
type of analysis analysis> Transient>OK>Full>OK
26. Determine the initial UM>Select>Entities>[ Select Nodes>By
temperature of the ingot. Num\pick>OK]
The initial temperature of the
ingot is set in the nodes In the window that appears, select Box,
belonging to the ingot, for then use the mouse to select the nodes of
which they are preliminarily the ingot (steel)]> OK
selected with the Select
command
27. Displaying selected nodes on UM>Plot>Nodes
the screen
28. Enter start temperature MM>Solution>Define
become Loads>Apply>Initial Conditions>Define
4
 [In the window that appears, click Pick
All (in all selected nodes), Select Temp in
Lab, Enter 1480 in Value]> OK
29. Activate the nodes belonging UM>Select>Entities>Nodes>Invert>Can
to the sand using the invert cel
operation - for a sand mold
30. Updating the working UM>Plot>Replot
window
31. Enter start temperature sand MM>Solution>Define
Loads>Apply>Initial Condition>Define
[In the window that appears, click Pick
All (in all selected nodes), Select Temp in
Lab, Enter 293 in Value]> OK
32. We set the conditions for UM> Plot > Lines
heat transfer at the sand-air MM>Solution>Define Loads>Apply>
boundaries Thermal>Convection>On lines [Mark
three lines on external border sand-
air]>OK
[Enter VALI =0.4 (heat transfer
coefficient). Enter VAL2I =293 (air
temperature)]> OK
33. Setting the duration of the MM>Solution>Load step options>Time /
process, the value of the time Frequency>Time -Time step
step and other parameters of [TIME]= 600
the task. [DELTIM]= 10 (recommended step)
Observation time (600 [KBS]- stepped (boundary conditions are
seconds) is set to automatic, constant in time)
variable time step [AUTOTS] -ON
[DELTIM]= 5 ( minimum step )
Max time step size = 15 ( maximum step
)OK

MM>Solution>Load step options>Time /

Frequency>Time integration> amplitude
decay(newmark parameters)> [THETA
=1]>OK
34. We tell the machine to save MM>Solution>Load step options -
the results for each step of Output controls>DB / Results file
the solution [Press Every substep for FREQ (count
results are stored at each time step)]> OK
35. Saving a file MM>File>Save as [Link]
36. We start the task on the MM>Solution>Solve>Current LS
account
5
 37. Turn on the numbering of UM>Plot Controls>Numbering
nodes on the screen Mark V
node numbers > On (enable numbering of
nodes on the screen)
[/NUM] →Colors & Numbers>OK
38. Show Items UM>Plot →Elements
39. Let's select a node that UM>Parameters>Scalar parameters
approximately corresponds [ In Selection we type
to the center of the symmetry cnt_pt=node(0.16,0.06,0)]>
plane (see figure); Accept>Close
center coordinates
(0.16,0.06,0)
To do this, assign the
variable cnt_pt the number of
the node with these
coordinates
40. We display a graph of the MM>Time/History Postproc>Define
dependence of temperature in variables>Add>Nodal Dof Results>OK
this node on time (add a new variable)> Enter cnt_pt > OK
Node field contains the node number>
OK > Close

MM>Time/History Postproc>Graph
Variables
Enter parameter 2 in NVAR1

4 Implementation of the task in the programming language APDL

Table 2 - The procedure for performing laboratory work in the APDL programming
language

N Team Description Team

o.
1. Set the title of the task;
TITLE – command /TITLE,Slitok
Slitok – header
2. Enable Thermal Analysis Filter KEYW,PR_THERM,1
(only items related to this type of
calculation will be available in the main
menu)
3. Choice of element type; /PREP7
/ PREP7 - go to the Preprocessor section
6
 ET – command; ET,1,PLANE55
1 – ordinal number of element type;
Plane 55 is the name of a 2D element in
the ANSYS library.
4. Setting properties for sand
(Material No. 1)
Set value for thermal conductivity:
MPTEMP is a command for creating a MPTEMP,1,0
temperature table;
MPDATA – a command to enter a value MPDATA,KXX,1,,0.35
into a table;
KXX – thermal conductivity;
1 – material number;
0.35 – numerical value of thermal
conductivity

Set value for specific heat capacity

MPDATA – a command to enter a value
into a table; MPDATA,C,1,,850
C – specific heat capacity
1 – material number;
850 – numerical value of specific heat

Set a value for the density;

MPDATA – a command to enter a value
into a table; MPDATA,DENS,1,,1600
DENS – Density
1 – material number;
1600 – numerical density value
5. Addition of material 2 (steel) This command cannot be
executed using the command line
6. Specifying a tabular dependence of steel
thermal conductivity on temperature
MPTEMP is a command for creating a MPTEMP,1,273
temperature table; MPTEMP,2,780
1,2,3,4 – temperature number MPTEMP,3,1300
273,780,1300,1480 – numerical value of MPTEMP,4,1480
temperatures

MPDATA – a command to enter a value MPDATA,KXX,2,,15

into a table; MPDATA,KXX,2,,18
KXX – thermal conductivity; MPDATA,KXX,2,,31
2 – material number MPDATA,KXX,2,,34
7
 15,18,31,34 – numerical value of
thermal conductivity
7. Specifying a tabular dependence of the
specific heat capacity of steel on
temperature MPTEMP is a command for MPTEMP,1,273
creating a temperature table; MPTEMP,2,780
1,2,3,4 – temperature number MPTEMP,3,1300
273,780,1300,1480 – numerical value of MPTEMP,4,1480
temperatures
MPDATA – value input command; MPDATA,C,2,,450
C – specific heat MPDATA,C,2,,550
2 – material number MPDATA,C,2,,620
450, 550,620,640 – the numerical value MPDATA,C,2,,640
of the specific heat
8. Displaying Material Properties as a This command cannot be
Graph (Thermal Conductivity) executed using the command line
9. Displaying Material Properties as a This command cannot be
Graph (Specific Heat Capacity) executed using the command line
10. Building points (vertices of the sand
model) K,1,0,0,0,
K – team K.2, [Link],
1 – point number K,3,0.10,0.12,0,
0,0,0 point coordinates X,Y,Z K,4,0,0.12,0,
11. Enable point numbering
/PNUM – command; /PNUM,KP,1
KP – points
1 – enable

Enable Surface Numbering

/PNUM – command; /PNUM,AREA,1
AREA – surface
1 – enable
12. Moving the origin symbol to the upper
left corner of the graphics window:
/TRIAD – triad positioning command /TRIAD,LTOP
LTOP – display triad in upper left
corner
13. Create a surface by points:
FLST – a command that determines the FLST,2,4,3
parameters for selecting model elements
2 – parameter number
4 – the number of selected elements of
the model
8
 3 – indicate that points will be selected
FITEM - a command that indicates FITEM,2,1
which element of the model is selected FITEM,2,2
2 – parameter number FITEM,2,3
1,2,3,4… – numbers of points that are FITEM,2,4
activated
A is a command that creates a surface by
points
P51X – the surface will be formed by A,P51X
those elements that were selected before
14. Saving a file SAVE
15. Create an area for steel:
RECTNG – command; RECTNG,0.04,0.22,0.04,0.08,
0.04 is the X coordinate of the lower left
corner;
0.22 is the X coordinate of the lower
right corner;
0.04 is the Y coordinate of the upper left
corner;
0.08 – Y coordinate of the upper right
corner;
16. Perform "Overlap" areas (overlap). This
operation separates the intersecting parts
of existing areas.
FLST – a command that determines the
parameters for selecting model elements FLST,2,2,5,ORDE,2
2 – parameter number
2 – the number of selected elements of
the model
5 – indicate that areas will be selected
ORDE - The data is in an ordered list
2 – the length of the list, the same as the
number of selectable elements of the FITEM,2,1
model FITEM,2,-2
FITEM – a command that indicates
which element of the model is selected
2 – parameter number
1 – number of the first surface to be
activated
-2 – the sign "-" means a range of
values, i.e. 1 to 2 AOVLAP,P51X
AOVLAP – overlap operation command
P51X – all previously selected elements
9
17. Removing an extra area.
ADELE – a command that deletes ADELE,3,,,1
selected surfaces
3 – number of the removed surface
1 – delete not only the surface but also
everything that belongs to it
18. We divide the structure into elements
with a given element side size: ESIZE,0.015,0,
ESIZE – command;
0.015 – default element size
19. Divide into elements the area occupied
by sand

In this case, this area will be assigned

the properties of material No. 1 by
default.

MSHKEY - a command that determines MSHKEY,0

the type of partition;
0 – partition type free;
ASEL – surface selection; ASEL,,,,5
5 – surface number
AMESH – command for splitting AMESH,all
surfaces;
ALL – split all active surfaces
20. We define the machine that all the
following actions when splitting will be
for material No. 2

MAT – a command that sets the current MAT,2

material number
2 – material number
21. Display Surfaces APLOT
22. Breakdown into elements of the area
occupied by steel
MSHKEY - a command that determines MSHKEY,0
the type of partition;
0 – partition type free;
ASEL - surface selection; ASEL,,,,4
4 – surface number
AMESH – command for splitting AMESH, all
surfaces;
ALL – split all active surfaces
10
23. Highlight different materials with
different colors
/ NUMBER – command that determines /NUMBER,1
how the numbering is displayed on the
display screen
1 – display only colors

/ PNUM – command to display material /PNUM,MAT,1

numbers
MAT – display of material number
1 – enable display of material number
24. Saving a file SAVE
25. Selecting a non-stationary type of
analysis / SOL – Go to the solution /sol
section ;
ANTYPE – command; ANTYPE,4
4 – non-stationary type of analysis.
26. Determine the initial temperature of the
ingot.
Initial temperature of the ingot;
is specified at the nodes belonging to the
ingot, i.e. material number 2

ESEL is the element selection ESEL,S,MAT,,2

command.
S is a parameter indicating that the
selection will be made again from all
existing elements of the model.
MAT – a parameter indicating that the
selection will be made by material
number;
2 – material number.
NSLE,S
NSLE – command to select nodes
belonging to the selected elements.
S is a parameter indicating that the
selection will be made again from all
existing elements of the model. (in our
case, from all elements belonging to
material No. 2)
27. Displaying selected nodes on the screen NPLOT

11
28. Enter start temperature become
IC – command to enter the initial state IC,all,TEMP,1480,
of the model
ALL – definition of the initial state for
all previously selected elements of the
model
TEMP – enter the initial temperature
1480 – numerical temperature value
29. Activate the nodes belonging to the sand
using the invert operation - for a sand
mold
NSEL – a command by which nodes are NSEL, INVE
selected
INVE – invert
30. Updating the working window /REPLOT
31. Enter start temperature sand
IC – command to enter the initial state IC,all,TEMP,293,
of the model
ALL – determination of the initial state
for previously selected model elements
293 – numerical value of temperature
ALLSEL – command for selecting
model elements; ALLSEL,ALL
ALL – activate all elements of the
model;
32. We set the conditions for heat transfer at
the sand-air boundaries

Show only lines LPLOT

lsel – line selection command lsel,s,line,,1

s – select again from all elements of the lsel,a,line,,3
model lsel,a,line,,4
a – select in addition to those lines that
have already been selected;
line – a parameter indicating that we
will select lines by their numbers;
1, 3, 4 – line numbers.

SFL – Command on task. surface load SFL,ALL,CONV,0.4, .293

on the line;
ALL – definition of the initial state for
all previously selected elements of the
12
 model
Conv – apply heat exchange with the
environment;
293 – ambient temperature
33. Setting the duration of the process, the
value of the time step and other
parameters of the task.
Observation time (600 seconds) is set to
automatic, variable time step

TIME – a command that sets the time of

the process; TIME,600
600 – total process time;
AUTOTS – a command indicating the
choice of automatic time for one AUTOTS,1
solution step
1 – enable automatic solution step
selection
DELTIM – a command that sets the
time; one step solution; DELTIM,10,5,15,1
10 – time of one step;
5 – minimum step time
15 – maximum step time

KBC – indicating command;

dependence of boundary conditions on KBC,1
time;
1 – boundary conditions do not depend
on time. TIMINT,1
TINTP,0.005,,,1,,,
enable integration effects
34. We tell the machine to save the results
for each step of the solution
OUTRES – command; OUTRES,ALL,ALL,
All – save all solution results;
All – save all steps of the solution.
35. Saving a file SAVE
36. We start the task on the account SOLVE
37. Turn on the numbering of nodes on the
screen /PNUM,NODE,1
/PNUM – command; /NUMBER,0
NODE – a parameter indicating that the
numbering for nodes;
13
 1 – enable numbering
38. Show Items EPLOT
39. Let's select a node that approximately
corresponds to the center of the
symmetry plane (see figure);
center coordinates (0.16,0.06,0)
To do this, assign the variable cnt_pt the *SET,cnt_pt,node(0.16,0.06,0)
number of the node with these
coordinates
*SET – variable setting command
cnt_pt – variable name
node(0.16,0.06,0) – determine the node
number with x,y,z coordinates equal to
0.16,0.06,0
40. NSOL – a command that determines the /POST26
parameter of the solution result on the NSOL,2,cnt_pt,TEMP,
chart PLVAR2,,,,,,,,,,
2 – parameter number
cnt_pt – node number for which the
chart will be generated
TEMP – indicate that we are displaying
the temperature dependence on the
graph
graph

14