Computational Fluid Dynamics for Manufacturing Processes 7.5 credits

The course treats fundamentals of CFD and heat transfer, and methodologies for solving a broad range of multi-disciplinary engineering problems in the context of manufacturing process design, via application of CFD and thermal simulation tools in design analysis. The effects of different fluid flow regimes and thermo-physical properties of materials are studied. The course includes simulation laboratory sessions formed as case studies (e.g. COMSOL Multiphysics, Flotherm, MAGMASOFT) and laboratory measurements serving e.g. for the purposes of CFD model calibration/input parameter generation. The course includes the following elements: - Steady state and transient heat transfer, heat transfer modes and thermal resistance network applications. - Overview of Navier-Stokes equations, and numerical solution methods. - CFD model validation and virtual prototyping methodology. - Flow and heat transfer simulation of mold filling and solidification in gravity casting. - Fluid flow in porous media, including local thermal non-equilibrium conditions, and application to component casting. - Simulation models for heat treatment process design (e.g. annealing) of metallic components. - Simplified phase transformation models and their application to manufacturing process simulation, e.g. laser cladding. - Application of fluid flow and heat transfer models for polymer component manufacturing.