A finite element simulation of metal flow in moulds

Abstract

SUMMARYNumerical tools for simulating the casting process are employed in an increasing manner by foundry engineers in order to understand and improve casting techniques. The correct simulation of metal flow and temperature profiles during filling is an important part of an overall numerical simulation kit which includes solidification and residual stress evaluations.In this study, we develop a two-dimensional finite element model for studying metal flow and temperature fields during filling of mould cavities. A proper choice of turbulent/laminar model, correct tracking of metal free surface and evaluation of temperature to include metal-air-sand interaction are some of the essential features of the model.

Computation of mould filling processes with a moving Lagrangian interface technique

“…In the context of ÿxed-mesh ÿnite element methods, one of the most common ways of updating the interface has been using a volume of uid (VOF) [1][2][3][4][5][6], where an advection equation is considered to calculate the time-evolution of a pseudo-concentration function. To prevent numerical oscillations that might be generated in solving an advection-dominated problem with a standard Galerkin formulation, methods that stabilize the formulation need to be applied.…”

“…Among the stabilized methods used for this purpose by other researchers are the Taylor-Galerkin and streamline-upwind=Petrov-Galerkin (SUPG) approaches (see References [3][4][5]). These approaches must be supplemented with techniques that reduce the smearing of the pseudo-concentration proÿle and yield more accurate representation of the interface (see References [2][3][4][5]). In comparison, in the ÿxed-grid ÿnite di erence level set methods (see References [7; 8]), a distance reinitialization procedure is used to redeÿne the pseudo-concentration function, assuring that it does not become too at or too steep near the interface.…”

Numerical Simulation of Incompressible Flows With Moving Interfaces

“…In fact, this notion of pseudoconcentration function can be extended 11 to any continuous and monotonic scalar field F on the domain with the index value taken on the interface (see Figure 4(b)).…”

Two-Dimensional Non Newtonian Fluid Injection Moulding Filling Improved With a Cvfem/Vof Method

“…Z is expressed as an exponential function of the global coordinate x and the Peclet number (9): An implicit Euler scheme, added to the previous description for the spatial integration, is used in order to integrate the transient term of Equation (4). In this way a linear system of algebraic equations is generated and then solved through the SOR Gauss-Seidel iterative method.…”

“…In order to verify the proposed scheme and the implemented numerical code, the filling process proposed by Dhatt et al [4] is replicated. In this process, a fluid subjected to gravity enters to a step cavity with a constant velocity (0.1 m/s).…”