Modeling the effect of mould wall roughness on the melt flow simulation in casting process

Abstract

In this investigation a computational model has been developed which includes heat and mass transfer as well as effects of backpressure, and mould wall friction for the simulation of incompressible flow with free surfaces in mould cavity filling. The simulation of flow with free surfaces is based on the SOLA-VOF numerical algorithm, utilizing the finite difference method. The solid and free boundary conditions have been modified and a new algorithm has been developed to calculate the effect of cavity pressure and wallslip ratio, during mould filling. In this algorithm, the effect of wall-slip ratio on filling pattern has been modeled with an experimental function. In order to verify the computational results, the casting of an aluminum alloy within a transparent mould has been carried out and the mould erosion at different times has been recorded. A series each moulds with different grain fineness number were used to take into account the effect of surface roughness on flow pattern, the amount of erosion and the impact of the molten metal on the sand mould, using a photograph technique. The comparison between the experimental and the simulation results of sequence filling of a sand casting shows a good level of consistency that confirms the accuracy of the model for predicting erosion of the mould material.

Modeling and Simulation with Experimental Validation of Temperature Distribution during Solidification Process in Sand Casting

“…Pequet et al [6] studied the defects formation during solidification of Al alloy using ABAQUS and showed that most of the defects formed where the metal solidified last. Mirbagheri et al [7] has studied the melt flow and effect of mould roughness of sand mould. Computational results were verified by casting of an aluminum alloy within a transparent mould and the mould erosion at different times has been recorded.…”

The Effect of an Abrupt Change in the Magnetic Field on Bingham Fluid Flow in a Flat MHD Channel

“…В ра-ботах [3,4] проведено исследование процесса заполнения вязкопластичной средой осесим-метричных объемов методом литья под давлением. Задача о заполнении прямоугольных каналов ньютоновской жидкостью в случае, когда направления движения и силы тяжести совпадают, рассматривалась в [5][6][7], а в случае, когда они противоположны, -в [8][9][10][11].…”

Multiphysics modelling of manufacturing processes: A review

“…CFD has been extensively used in metal casting and simulating the flow of molten metals in moulds. [3][4][5][6] Reilly et al 7,8 have critically reviewed the role of CFD in defect entrainment in the shape casting process and summarized different numerical approaches used in different commercial packages, that is, MAGMASOFT 9 and FLOW-3D. 10 Another example of fluid flow analysis in modelling of manufacturing processes has been given by Zhang and Wu, 11 in which they investigated the effect of fluid flow in the weld pool on the numerical simulation accuracy of the thermal field in hybrid welding.…”