Numerical modeling of solidification process taking into account the effect of air gap

Skrzypczak, Tomasz; Węgrzyn-Skrzypczak, Ewa; Sowa, L.

doi:10.1016/j.amc.2017.11.023

Cited by 12 publications

(29 citation statements)

References 11 publications

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“…It was assumed that the solidification front is mushy. The mathematical model is based on solving the following system of equations in a cylindrical axisymmetric coordinate system [2,[4][5][6][7][8][9][10]: -the Navier-Stokes equations:…”

Section: The Mathematical Model Of the Casting Solidification Taking mentioning

confidence: 99%

“…where: Ta In the applied model of solid phase growth, the internal heat sources are not come evident in the equation of heat conductivity (3), because they are in the effective specific heat of the mushy zone [2,[7][8][9][10]. The above equations were solved by the finite element method in the weighted residuals formulation [2,5,[7][8][9][10]. In the numerical simulations, coupling of the thermal and flow phenomena by change in the thermophysical parameters of metals alloy depending on the temperature, has been taken into consideration.…”

Section: The Mathematical Model Of the Casting Solidification Taking mentioning

confidence: 99%

“…The work analysed the formation of a casting by gravitational pouring of molten metal into a metal mould, but the development of other casting methods has recently been devoted a lot of attention, mainly continuous casting [1,2] or the lost-wax casting technology [3]. Direct examining of the phenomena occurring during the casting process is difficult due to the lack of optical access and high temperature, which is why computer simulation seems to be a good solution to this problem [1,2,[4][5][6][7][8][9][10][11][12]. In order to obtain an effective numerical solution to the problem under investigation, the number of analysed phenomena should be limited to the most important ones which have a direct impact on the quality of the casting.…”

Section: Introductionmentioning

confidence: 99%

“…This requires the formulation of adequate mathematical model that takes into account the mutual influence of thermal and flow phenomena in the process of filling the cavity of the casting mold and after its completion [2,[4][5][6][7]. Some researchers neglect in the numerical analysis of the casting process the period of filling the mold cavity with liquid metal, assuming as the initial condition for the numerical calculation that the mould cavity is fully filled [8][9][10][11]. Other researchers in turn, focus in their research on the analysis of the formation and evolution of a shrinkage cavity or other defects of the casting process [3,[10][11][12].…”

Section: Introductionmentioning

confidence: 99%

“…Some researchers neglect in the numerical analysis of the casting process the period of filling the mold cavity with liquid metal, assuming as the initial condition for the numerical calculation that the mould cavity is fully filled [8][9][10][11]. Other researchers in turn, focus in their research on the analysis of the formation and evolution of a shrinkage cavity or other defects of the casting process [3,[10][11][12].…”

Section: Introductionmentioning

confidence: 99%

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Computer evaluation of the influence of liquid metal movements on defects formation in the casting

2019

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This paper concerns the modelling of the solidification process including the phenomena of heat transfer and fluid flow during the initial stage of the metal casting process. During this period, the molten metal motions have an essential influence on solidification kinetics. An analysis of solidification kinetics, by determining the velocity and temperature fields in a system of riser-casting was made. Velocity fields were obtained by solving the momentum equations and the continuity equation, while the thermal fields were obtained by solving the conduction equation containing the convection term. After completion of the filling process the main solidification of molten metal takes place and its shrinkage. The phenomenon of casting shrinkage cannot be avoided, but it is possible to minimize its negative effects on the casting quality. One with ways to solve this problem is to design the mould in such a way that the solidification proceeds in accordance to the assumed direction and finished in the riser. Generally, the aim of search is to obtain a casting without shrinkage defects.

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Section: The Mathematical Model Of the Casting Solidification Taking mentioning

confidence: 99%

Section: The Mathematical Model Of the Casting Solidification Taking mentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

See 3 more Smart Citations

Computer evaluation of the influence of liquid metal movements on defects formation in the casting

2019

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Mechanical Wave Propagation in Solidifying Metals: Physico‐Mathematical Model and Numerical Tests

Chen

Wang

2023

Advcd Theory and Sims

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Despite the widespread application of mechanical waves in solidifying metals, the wave propagation laws in melt and the motion patterns of melts are unclear, which has seriously hindered the development of vibration solidification treatment. It is difficult to solve the wave propagation because of the spatial heterogeneity and the intrinsic viscoelasticity of solidifying metals. In this paper, a physico-mathematical model is developed by coupling the unsteady temperature field and the integral Hooke-Kelvin model unifying various rheological models during solidification, and simplifies to wave equations by introducing memory factors. Then, the wave equations are solved by a staggered-grid high-order difference method. Subsequently, the propagation laws of mechanical waves in a large casting and a feeding channel during solidification are analyzed, eventually verified by casting experiments. It is shown that the viscoelasticity of solidifying metals is significant for the wave field. In the large casting, both displacements and stresses exhibit complex multi-lobe patterns. In the feeding channel, the formation of micropores between the quasi-liquid and the quasi-solid phase and the feeding improvement by vibrations are well explained by simulation. The numerical model is a novel reliable method to theorize the solidification under vibration and expands the potential applications of vibration.

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The influence of the riser dimensions on the effectiveness of feeding solidifying cast elements

2019

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The mathematical model and numerical simulation results of metals alloy solidification process based on the finite element method (FEM) are presented in this paper. After completion of the mould filling process the main solidified of molten metal takes place and its shrinkage. The phenomenon of casting shrinkage cannot be avoided. However, it is possible to minimize the occurrence of its negative effects on the casting quality. The phenomenon of shrinkage defects formation was included in the numerical calculations and they were tried to reduce them. It is important aspect of this work which makes possible the prediction of the location of the casting defect depending on shape of the riser. The results of computer calculations of the solidification process of the three-dimensional casting together with the conical or cylindrical riser are discussed in detail and presented.

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Numerical modeling of solidification process taking into account the effect of air gap

Cited by 12 publications

References 11 publications

Computer evaluation of the influence of liquid metal movements on defects formation in the casting

Computer evaluation of the influence of liquid metal movements on defects formation in the casting

Mechanical Wave Propagation in Solidifying Metals: Physico‐Mathematical Model and Numerical Tests

The influence of the riser dimensions on the effectiveness of feeding solidifying cast elements

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