Numerical Study on Mold Filling Process of Casting

2008 ◽  
Vol 575-578 ◽  
pp. 87-92
Author(s):  
Xiao Qiang Pan ◽  
Hong Zhu Sun ◽  
Jun Da Chen ◽  
Yu Ling Zhu
Keyword(s):  
Numerical Simulation ◽  
Initial Conditions ◽  
Numerical Study ◽  
Solidification Process ◽  
Mold Filling ◽  
General Purpose ◽  
Filling Process ◽  
Numerical Heat Transfer ◽  
Multiphase Fluid Flow ◽  
Multiphase Fluid

Techniques of numerical simulation on mold filling process of casting are investigated in this paper. The mathematical model is formed on the ground of some selected theories in computational fluid dynamics (CFD), Numerical Heat Transfer (NHT) and computational methods to interfacial tracking. The discrete solution to the governing equations appeals to Finite Volume Method (FVM) on structured mesh. As for viscous turbulence flow and multiphase fluid flow in mold filling, engineering turbulence model and Volume of Fluid (VOF) method are adopted in the algorithms, respectively. As a debut, the general-purpose CFD software is used to establish the practicable mechanical model for the simulation. By means of numerical simulation, variation and distribution of velocity, temperature, stress and configuration of casting, etc. with respect to time and space in the filling process can be quantitatively analysed in detail, which is helpful for engineers to optimize their design of technics with less time and less cost and is meaningful to provide the subsequent simulation, solidification process of casting, with initial conditions.

Numerical Study of an Impact Oscillator

1995 ◽  
Author(s):  
Kannan Marudachalam ◽  
Faruk H. Bursal
Keyword(s):  
Dynamical Systems ◽  
Numerical Algorithm ◽  
Initial Conditions ◽  
Numerical Study ◽  
Harmonic Excitation ◽  
General Purpose ◽  
Constrained Systems ◽  
Global Dynamics ◽  
Impact Oscillator ◽  
Stick Slip

Abstract Systems with discontinuous dynamics can be found in diverse disciplines. Meshing gears with backlash, impact dampers, relative motion of components that exhibit stick-slip phenomena axe but a few examples from mechanical systems. These form a class of dynamical systems where the nonlinearity is so severe that analysis becomes formidable, especially when global behavior needs to be known. Only recently have researchers attempted to investigate such systems in terms of modern dynamical systems theory. In this work, an impact oscillator with two-sided rigid constraints is used as a paradigm for studying the characteristics of discontinuous dynamical systems. The oscillator has zero stiffness and is subjected to harmonic excitation. The system is linear without impacts. However, the impacts introduce nonlinearity and dissipation (assuming inelastic impacts). A numerical algorithm is developed for studying the global dynamics of the system. A peculiar type of solution in which the trajectories in phase space from a certain set of initial conditions merge in finite time, making the dynamics non-invertible, is investigated. Also, the effect of “grazing,” a behavior common to constrained systems, on the dynamics of the system is studied. Based on the experience gained in studying this system, the need for an efficient general-purpose numerical algorithm for solving discontinuous dynamical systems is motivated. Investigation of stress, vibration, wear, noise, etc. that are associated with impact phenomena can benefit greatly from such an algorithm.

Conjugate Heat Transfer and Effects of Interfacial Heat Flux During the Solidification Process of Continuous Castings

2003 ◽  
Vol 125 (2) ◽  
pp. 339-348 ◽  
Author(s):  
M. Ruhul Amin ◽  
Nikhil L. Gawas
Keyword(s):  
Heat Transfer ◽  
Continuous Casting ◽  
Cooling Rate ◽  
Solidification Process ◽  
Air Gap ◽  
Gap Formation ◽  
Continuous Casting Mold ◽  
Withdrawal Velocity ◽  
Multiphase Fluid Flow ◽  
Multiphase Fluid

Multiphase fluid flow involving solidification is common in many industrial processes such as extrusion, continuous casting, drawing, etc. The present study concentrates on the study of air gap formation due to metal shrinkage on the interfacial heat transfer of a continuous casting mold. Enthalpy method was employed to model the solidification of continuously moving metal. The effect of basic process parameters mainly superheat, withdrawal velocity, mold cooling rate and the post mold cooling rate on the heat transfer was studied. The results of cases run with air gap formation were also compared with those without air gap formation to understand the phenomenon comprehensively. The current study shows that there exists a limiting value of Pe above which the effect of air gap formation on the overall heat transfer is negligible.

Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting

2011 ◽  
Vol 121-126 ◽  
pp. 254-258
Author(s):  
Bai Yang Lou ◽  
Fang Li Liu ◽  
Kang Chun Luo
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Casting Defects ◽  
Casting Simulation ◽  
Pressure Die Casting ◽  
Filling And Solidification

The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

Numerical Simulation of Dynamic Process under Low Pressure Casting Based on Two Phase Flow

2015 ◽  
Vol 727-728 ◽  
pp. 358-361
Author(s):  
Shan Guang Liu ◽  
Fu Yang Cao ◽  
Xin Yi Zhao ◽  
Yan Dong Jia ◽  
Zhi Liang Ning ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Particle Image Velocimetry ◽  
Particle Image ◽  
Mold Filling ◽  
Phase Flow ◽  
Pressure Casting ◽  
Filling Process ◽  
Two Phase ◽  
Image Velocimetry ◽  
Low Pressure Casting

It has been proved that the mold filling under low pressure casting can be described by the second order nonlinear differential equations characterized by damping oscillations. To obtain higher accuracy of the velocity field, the mold filling process with damping oscillations should be considered. A computational model taking the liquid level droping in the crucible into account based on two phase flow for filling process of damping oscillations is presented in this paper. Hydraulic simulation with the particle image velocimetry was adopted to verify the numerical simulation result. It is proved that the nemuerical simulation results used the presented model perfecly match with the particle image velocimetry results. Liquid level droping in crucible is the main reason for damping oscillations in mold filling. Velocity oscilations can be eliminated when the melt flow across a sudden expansion section. The detailed flow field based on the presented model can provide guidance to optimize the process parameters.

scholarly journals Parallel partitioning algorithm for numerical simulation of gas-liquid two-phase flow during the mold filling process

2019 ◽  
Vol 37 ◽  
pp. 513-519
Author(s):  
Yongjia Zhang ◽  
Xiang Gao ◽  
Xu Shen ◽  
Zhiwei Huang ◽  
Yajun Yin ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Two Phase Flow ◽  
Mold Filling ◽  
Phase Flow ◽  
Filling Process ◽  
Two Phase ◽  
Partitioning Algorithm

Numerical Simulation of Mold Filling and Solidification Process for Beam Blank Continuous Casting

2012 ◽  
Vol 538-541 ◽  
pp. 506-509
Author(s):  
Yan Juan Jin ◽  
Xiao Chao Cui ◽  
Zhu Zhang
Keyword(s):  
Velocity Field ◽  
Continuous Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Filling Process ◽  
Continuous Casting Mold ◽  
Commercial Code ◽  
Solidification Speed ◽  
Filling And Solidification

Mold filling and solidification of molten steel for 750mm×450mm×300mm continuous casting mold of single SEN and double SEN are simulated by using CFD commercial code Flow-3d. The distributing diagrams of velocity field and temperature field and the location and shape diagrams of free-surface during mold filling process are obtained. Influences of single SEN model and double SEN model on velocity field and solidification are analyzed. It is found that double SEN model can lighten circumfluence intensity at the upper of mold, quicken solidification speed of steel liquid in the mold, which is favorable to improving the quality of billet and enhancing pull speed.

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