Simulation of melt flow in coated mould cavity in the casting process

Mirbagheri, S. M. H.; Esmaeileian, H.; Serajzadeh, S.; Varahram, N.; Davami, P.

doi:10.1016/s0924-0136(03)00649-6

Cited by 34 publications

(27 citation statements)

References 4 publications

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“…The 3D fluid dynamics analysis package (FIDAP) (Fluid Dynamics International, Inc., Evanston, IL) model includes the shear stress imposed on the flux steel interface by flow velocities calculated in the molten steel pool. Mirbagheri et al [17] investigated the simulation of 3D flow of incompressible molten metal in a mold cavity. The comparison between the experimental and the numerical results shows good agreement confirming the accuracy of the model.…”

Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Cold Modeling experiments on Centrifugal Casting

Keerthiprasad

Murali²,

Mukunda

et al. 2010

Metall Mater Trans B

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KESTUR SADASHIVAIAH KEERTHIPRASAD, MYSORE SEETHARAM MURALI, PUDUKOTTAH GOPALIENGAR MUKUNDA, and SEKHAR MAJUMDARIn a centrifugal casting process, the fluid flow eventually determines the quality and characteristics of the final product. It is difficult to study the fluid behavior here because of the opaque nature of melt and mold. In the current investigation, numerical simulations of the flow field and visualization experiments on cold models have been carried out for a centrifugal casting system using horizontal molds and fluids of different viscosities to study the effect of different process variables on the flow pattern. The effects of the thickness of the cylindrical fluid annulus formed inside the mold and the effects of fluid viscosity, diameter, and rotational speed of the mold on the hollow fluid cylinder formation process have been investigated. The numerical simulation results are compared with corresponding data obtained from the cold modeling experiments. The influence of rotational speed in a real-life centrifugal casting system has also been studied using an aluminum-silicon alloy. Cylinders of different thicknesses are cast at different rotational speeds, and the flow patterns observed visually in the actual castings are found to be similar to those recorded in the corresponding cold modeling experiments. Reasonable agreement is observed between the results of numerical simulation and the results of cold modeling experiments with different fluids. The visualization study on the hollow cylinders produced in an actual centrifugal casting process also confirm the conclusions arrived at from the cold modeling experiments and numerical simulation in a qualitative sense.

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Section: Introductionmentioning

confidence: 99%

Numerical Simulation and Cold Modeling experiments on Centrifugal Casting

Keerthiprasad

Murali²,

Mukunda

et al. 2010

Metall Mater Trans B

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“…(ii) For surface cell (0 < F < 1): D i;j;k for free surface is satisfied by setting the surface cell pressure ðP cell Þ equal to the value obtained by a linear interpolation between gas pressure at the surface ðP S Þ and the pressure inside the fluid ðP N Þ [14,27].…”

Section: Finite Difference Approximationsmentioning

confidence: 99%

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

Mirbagheri¹,

Dadashzadeh²,

Serajzadeh³

et al. 2004

Applied Mathematical Modelling

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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.

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“…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.…”

Section: Introductionmentioning

confidence: 99%

Multiphysics modelling of manufacturing processes: A review

Jabbari

Baran

Mohanty³

et al. 2018

Advances in Mechanical Engineering

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Numerical modelling is increasingly supporting the analysis and optimization of manufacturing processes in the production industry. Even if being mostly applied to multistep processes, single process steps may be so complex by nature that the needed models to describe them must include multiphysics. On the other hand, processes which inherently may seem multiphysical by nature might sometimes be modelled by considerably simpler models if the problem at hand can be somehow adequately simplified. In the present article, examples of this will be presented. The cases are chosen with the aim of showing the diversity in the field of modelling of manufacturing processes as regards process, materials, generic disciplines as well as length scales: (1) modelling of tape casting for thin ceramic layers, (2) modelling the flow of polymers in extrusion, (3) modelling the deformation process of flexible stamps for nanoimprint lithography, (4) modelling manufacturing of composite parts and (5) modelling the selective laser melting process. For all five examples, the emphasis is on modelling results as well as describing the models in brief mathematical details. Alongside with relevant references to the original work, proper comparison with experiments is given in some examples for model validation.

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Simulation of melt flow in coated mould cavity in the casting process

Cited by 34 publications

References 4 publications

Numerical Simulation and Cold Modeling experiments on Centrifugal Casting

Numerical Simulation and Cold Modeling experiments on Centrifugal Casting

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

Multiphysics modelling of manufacturing processes: A review

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