Part I: Basic Considerations. Chapter 1: Introduction -- 1.1 Materials Processing and Manufacturing -- 1.2 Different Materials and Products -- 1.3 Underlying Transport Phenomena -- 1.4 Important Manufacturing and Materials Processing Techniques -- 1.4.1 Traditional Manufacturing Processes -- 1.4.2 Recent and Advanced Materials Processing Methods -- 1.5 Practical Aspects -- 1.6 Basic Thrust and Scope of the Book -- References. Chapter 2: Mathematical Modeling of Manufacturing Processes -- 2.1 Basic Aspects -- 2.2 Governing Equations -- 2.3 Common Challenges in Mathematical Modeling -- 2.3.1 Variable Properties -- 2.3.2 Viscous Dissipation -- 2.3.3 Buoyancy Effects -- 2.4 Additional Transport Mechanisms and Considerations -- 2.4.1 Non-Newtonian Fluids -- 2.4.2 Surface Tension Effects -- 2.4.3 Particulates and Powdery Materials -- 2.4.4 Phase Change -- 2.4.5 Chemically Reactive Materials -- 2.4.6 Complicated Geometry -- 2.4.7 Combined Mechanisms -- 2.4.8 Complex Boundary Conditions -- 2.5 Other Challenges -- References; Chapter 3: Numerical Modeling and Experimentation -- 3.1 Analytical Solution -- 3.2 Numerical Modeling -- 3.2.1 Accurate Imposition of Appropriate Boundary Conditions -- 3.2.2 Numerical Modeling of Complicated Regions -- 3.2.3 Modeling of Combined Mechanisms and Complex Transport Phenomena -- 3.2.4 Multiscale Modeling -- 3.3 Numerical Solution -- 3.4 Verification and Validation of the Model -- 3.5 Modeling of Manufacturing Systems -- 3.6 Numerical Simulation -- 3.7 Experimentation -- 3.8 Link Between Transport Processes and Product Characteristics -- References.
Part II: Different Manufacturing Processes. Chapter 4: Manufacturing Processes with Phase Change -- 4.1 Analysis -- 4.1.1 Interface Tracking -- 4.1.2 Enthalpy Method -- 4.2 Simple Conduction Models -- 4.3 One-Dimensional Solidification -- 4.4 Results for Multidimensional Problems -- 4.4.1 Interface Tracking: Transformed Grid Method -- 4.4.2 Enthalpy Formulation -- 4.4.3 Conjugate Transport -- 4.4.4 Experimental Studies -- 4.5 Continuous Casting -- 4.6 Alloys -- 4.7 Crystal Growing -- 4.8 Other Processes and Materials -- 4.9 Summary -- References; Chapter 5: Continuous Materials Processing -- 5.1 Basic Process -- 5.2 Heat Transfer Within the Moving Material -- 5.2.1 Analysis -- 5.2.2 Analytical and Numerical Results -- 5.3 Convective Transport Due to a Moving Surface -- 5.4 Conjugate Transport -- 5.4.1 Boundary-Layer Formulation -- 5.4.2 Solution of the Full Equations (Elliptic Formulation) -- 5.5 Buoyancy and Forced Flow Effects -- 5.6 Transient Effects -- 5.7 Experimental Work -- 5.8 Additional Aspects -- 5.9 Summary -- References; Chapter 6: Polymer Processing -- 6.1 Material Properties -- 6.2 Single Screw Extrusion -- 6.2.1 Two-Dimensional Model -- 6.2.2 Fully Developed Flow -- 6.2.3 Developing Flow -- 6.2.4 Three-Dimensional Transport -- 6.2.5 Axial Formulation -- 6.2.6 Tapered Screw -- 6.3 Residence Time -- 6.4 Mixing -- 6.5 Experimentation -- 6.6 Twin Screw Extrusion.
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This book focuses on advanced processing of new and emerging materials, and advanced manufacturing systems based on thermal transport and fluid flow. It examines recent areas of considerable growth in new and emerging manufacturing techniques and materials, such as fiber optics, manufacture of electronic components, polymeric and composite materials, alloys, microscale components, and new devices and applications. The book includes analysis, mathematical modeling, numerical simulation and experimental study of processes for prediction, design and optimization. It discusses the link between the characteristics of the final product and the basic transport mechanisms and provides a foundation for the study of a wide range of manufacturing processes. Focuses on new and advanced methods of manufacturing and materials processing with traditional methods described in light of the new approaches; Maximizes reader understanding of the fundamentals of how materials change, what transport processes are involved, and how these can be simulated and optimized - concepts not covered elsewhere; Introduces new materials and applications in manufacturing and summarizes traditional processing methods, such as heat treatment, extrusion, casting, injection molding, and bonding, to show how they have evolved and how they could be used for meeting the challenges that we face today.