Manufacturing processes for metals and polymers. Creation of process models based on momentum, heat and mass transfer. Model simplification by estimation and scaling. Example applications include casting, microstructure evolution, polymer molding and extrusion, and welding. Prerequisite: ME 320 and ME 330 or consent of instructor. 3 undergraduate hours.
1. Modeling Fundamentals: Uses of process models for design and manufacturing; modeling strategy, and structure of mathematical models; balance equations for mass, momentum, energy; and estimation, scaling, and model simplification
2. Heat Transfer: Governing equations and boundary conditions for conduction; transient conduction: semi-infinite body and slab; heat convection: Peclet number, boundary layers; and phase changes and solidification; Stefan condition
3. Fluid flow: Inertial and gravity effects; viscous-dominated Newtonian channel flows; Non-Newtonian flow phenomena; power-law fluid: constitutive equation and use in channel flows; extrusion die design; simplified-geometry models for mold filling; generalized Hele-Shaw model; and injection molding analysis
4. Heat transfer with fluid flow: Advection; Peclet number, applications in continuous casting; viscous dissipation; applications in polymer processing; Buoyancy-driven flows; applications in crystal growth; moving heat sources; applications in welding; and thermocapillary phenomena; applications in crystal growth
5. Mass transfer and microstructures: Balance equations for mass transfer; solidification of alloys: equilibrium phase diagrams, non-equilibrium solidification; solidification with diffusion: interfacial instability and microstructure development.
ME: MechSE or technical elective.
EM: Possible secondary field, with approval.