Numerical Simulation and Chaotic Analysis of an Aluminum Holding Furnace
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WITH the progress of computer technology, numerical algorithm and thermal theory, numerical simulation of aluminum alloying process has been developed rapidly. It is very important to understand thermal phenomena of metal holding process and improve holding equipment. Golchert et al.[1] investigated the effects of oxidant type on temperature field of an aluminum holding furnace. To raise heat efficiency, Belt[2] pointed out that the most effective method is to reduce fuel velocity which is based upon heat balance test of an aluminum holding furnace of aluminum casting industry. Pauty et al.[3] have done a lot of study work about numerical simulation of solid inclusions transport behavior in two flow situations: a holding flow and a pouring flow. The research group of Central South University[4–9] has conducted numerical simulation of aluminum holding furnaces from holding phase and electromagnetic stirring stage. Migchielsen[10] discussed that design choices of aluminum holding furnaces for different aluminum casting workshops in detail. JI-MIN WANG, Lecturer, SHEN LAN and RUI-JIAO TIAN, Graduate Students, TAO CHEN, JIE LI, and YAN-WU TU, Undergraduate Students, and WEN-KE LI, Associate Professor, are with the School of Energy and Environment, Anhui University of Technology, Maanshan, 243002 Anhui, P.R. China. Contact e-mail: [email protected] YUAN-YUAN ZHOU, Lecturer, is with the School of Business, Anhui University of Technology, Maanshan, 243002 Anhui, P.R. China. HONG-JIE YAN and JIE-MIN ZHOU, Professors, are with the School of Energy Science and Engineering, Central South University, Changsha, 410083 Hunan, P.R. China. Manuscript submitted July 3, 2013. Article published online August 12, 2014. 2194—VOLUME 45B, DECEMBER 2014
Based on the detailed investigation of the published papers, although the development of numerical simulation in the solidification process of non-ferrous metal or metallic material is very fast, the related literatures about the numerical simulation for aluminum alloy holding process are still less. Generally, the major function of aluminum holding furnaces is to make liquid aluminum be alloying within reasonable temperature range. Therefore, liquid aluminum must be firstly heated to near alloying temperature, and then melt temperature is kept constant by adjusting fuel mass flow about 1 hour, thereafter, melt temperature gradually drops to tapping temperature through turning off burners. During holding process, burners start high fire and low fire alternately. Especially, early literatures mainly inspected thermal characteristics of certain phase of aluminum holding furnaces, e.g., heating phase, holding stage or standing period. Therefore, thermal characteristics of thermal process of aluminum holding furnaces can not be revealed. What is more, burning capacity varies with melt temperature during production process. Thus, combustion instability of aluminum holding process would appear which may be measured by chaos theory. Zeng[11] employed an image processing method and nonlinear time series ana
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