Thermo-fluid simulation using particle method based on hand-pouring motion in casting process
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ORIGINAL ARTICLE
Thermo-fluid simulation using particle method based on hand-pouring motion in casting process Hitoshi Tokunaga 1
&
Yuichi Motoyama 1 & Kazuyo Iwamoto 1 & Toshimitsu Okane 1
Received: 6 February 2020 / Accepted: 20 September 2020 / Published online: 28 September 2020 # Springer-Verlag London Ltd., part of Springer Nature 2020
Abstract Casting simulators are widely used to evaluate casting designs. However, most simulators using conventional methods such as FDM or FEM entail difficulty in evaluating casting designs sufficiently based on ladle motions or an operator’s pouring motion because they do not readily accommodate dynamically changing wall boundaries and do not easily accommodate the ladle motion as input. For this study, the authors extended the thermo-fluid simulation based on particle method, an earlier proposed method, so that the measured ladle motion can be input. The authors measured an operator’s ladle motion using marker tracking technique for AR and executed thermo-fluid simulations using the proposed simulation method. Comparisons of the experiments and the simulation results clarified that the proposed method can accurately predict flow behaviors of the molten metal resulting from the ladle motion. Comparisons of the proposed simulation and the simulation with a conventional simulation using the inflow condition of the constant flow rate clarified the importance of executing the simulation based on the ladle motion for highaccuracy prediction of molten metal behavior. Keywords Aluminum alloy casting . Augmented reality (AR) . Pouring motion . Smoothed particle hydrodynamics (SPH) . Thermo-fluid simulation
1 Introduction Many casting processes used by human operators include hand pouring of molten metal with ladles. Differences of motions of various operators and differences of hand motions used each time engender differences of molten metal flow behavior, and consequently influence the quality of castings. To produce higher-quality castings, evaluating operator pouring motion is important. In recent years, many studies have simulated molten metal flow, heat transfer, solidification, and so on [1], based on which casting simulators have been developed. They are used widely to evaluate casting designs. Nevertheless, most use finite element method (FEM) or finite difference method (FDM). Such conventional simulators do not readily
* Hitoshi Tokunaga [email protected] 1
Advanced Manufacturing Research Institute, National Institute of Advanced Industrial Science and Technology (AIST), 1-2-1 Namiki, Tsukuba, Ibaraki 305-8564, Japan
accommodate the ladle motion, i.e., the operator’s pouring motion, as input. Therefore, most casting designers usually derive inflow conditions of constant flow rate and constant cross-sectional area from the amount of molten metal, the pouring time, or the pressure head and execute casting simulations under these conditions. Such simulators have difficulty predicting casting defects resulting from the operator’s pouring motion. Therefore, the simul
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