Computational modeling of mold filling and related free-surface flows in shape casting: An overview of the challenges in
- PDF / 196,640 Bytes
- 7 Pages / 612 x 792 pts (letter) Page_size
- 6 Downloads / 154 Views
THE modeling of solidification processes using computational techniques has engaged the attention of the ‘‘numerical’’ research community for over 40 years. This attention has been merited because of the significance of the industries using casting processes and their potential to produce components of very high integrity and controllable structure. The reason for the challenge in computational modeling of casting and related solidification-based processes arises from a range of key issues: (1) capturing the range of the interactions among a range of physical phenomena involving complex fluid flows, heat transfer with solidification (and melting phase change), electromagnetic fields, and nonlinear solid mechanics; (2) the representation of complex, fully three-dimensional (3-D) geometries; (3) the computation of simulation results within a practical timescale; and (4) the prediction of defects and structure and the consequence of the interacting physics, rather than just the flow, thermal, and stress fields themselves as a function of time. M. CROSS, Professor of Computational Modeling, D. McBRIDE, Research Officer, and T.N. CROFT and A.J. WILLIAMS, Senior Research Officers, are with the School of Engineering, University of Wales Swansea, Swansea SA2 8PP, United Kingdom. Contact e-mail: [email protected] K. PERICLEOUS, Professor, is with the Centre for Numerical Modelling and Process Analysis, University of Greenwich, Old Royal Naval College, London SE10 9LS, United Kingdom. J.A. LAWRENCE, Ph.D. Student, formerly with the Centre for Numerical Modelling and Process Analysis, University of Greenwich, Old Royal Naval College, is deceased. This article is based on a presentation made in the John Campbell Symposium on Shape Casting, held during the TMS Annual Meeting, February 13–17, 2005, in San Francisco, CA. METALLURGICAL AND MATERIALS TRANSACTIONS B
One of the key features of casting simulation is the prediction of the mold-filling phase of the process and its impact on subsequent stages of the process. The significance of this aspect of the process has not been lost on John Campbell,[1] who has campaigned almost continuously for the foundry industry to take control over the filling behavior of molds as the key to control over defects at all scales in the cast component. Recent work by Campbell and collaborators[2] reinforces this point once again in the manufacture of high-added-value Ni-based investment-cast turbine blades—he who controls the filling process minimizes the formation and extent of defects. It is, therefore, not surprising that the simulation of mold filling has provided such a source of challenges to the computational modeling community over what amounts to three decades or more. Much of this work has been charted by the proceedings[3–12] from the series of conferences on ‘‘Modeling of Casting, Welding, and Advanced Solidification Processes’’ (MCWASP), which began in 1980 and has run every couple of years since. In one of these recent meetings, Kothe et al.[13] have provided a useful review of free-surface flow tec
Data Loading...
