Numerical Method for Calculation of Complete Casting Processes—Part I: Theory

Abstract

This article presents a method for calculation of the complete casting process, including the pouring of the liquid metal into the mold, its solidification, the deformation of the solidified cast, the formation of airgaps between the cast and the mold and their influence on the heat transfer, and the residual stresses. An original phase-change procedure is developed, valid for an arbitrary number of pure metals and=or alloys. A collocated version of a segregated finite-volume method is used to calculate both the liquid metal flow and the deformations and stresses in solids.

Numerical Method for Calculation of Complete Casting Processes—Part II: Validation and Application

“…The presented test cases show that the method described in Part I [1] is capable of calculating all phases of a casting process, including pouring of liquid metal, its solidification, as well as predicting residual stresses in the cast after it has been removed from the mold.…”

“…Here, the method presented in Part I [1] is applied to a solidification of a drill head made of four metals with different physical properties and different enthalpytemperature dependencies. The object of the simulation is the analysis of stress development within the cast in order to avoid cracking.…”

“…Mathematical models and numerical simulations capable of describing and predicting important, strongly interacting features of a casting process could have great value for industries which use the process. In Part I of this study [1] we proposed a mathematical model and a numerical method which should be able to fulfill the task. Here, validation of the method and its application to real-life industrial cases are presented.…”

Transient Radiator Room Heating—Mathematical Model and Solution Algorithm

“…For the multiple-layer outer wall and room assembly, the finite volume method (FVM) discretization principles are used. Discretization of space, time, and equations is implemented according to [17,18]. The space domain is divided into the finite number of control volumes (CVs), not necessarily of the same size, where the calculation points are located at the cell centers (collocated variable arrangement).…”

“…Note that the first term on the right-hand side of Equation 10is the heat flux at the east cell face surface, while the second term represents the heat flux at the west cell face surface. The cell face value of conductivity, Equation 11, for example at cell face e, is according to [18] and is calculated as:…”