A Numerical Study of Simultaneous Mould Filling and Solidification in Casting Process

ABSTRACT

In this paper, we present a numerical model for simultaneous mould filling and solidification in a casting process. The model takes into consideration any phase change taking place during filling process. An implicit volume of fluid (VOF)-based algorithm has been employed for simulating the free surface flows during filling process, while the model for solidification is based on a fixed-grid enthalpy-based control volume approach. Solidification modelling is coupled with VOF through User Defined Functions developed in commercial fluid dynamics (CFD) code FLUENT 6.3.26. The role of strength of residual flow and temperature gradients within the solidifying domain, caused by the filling process, on the evolution of solidification interface are investigated. The model is demonstrated for the case of filling and solidification of a binary alloy, and the resulting evolution of mushy zone and macrosegregation are studied. The effects of process parameters related to filling, namely degree of melt superheat and filling velocity on macrosegregation in the cavity are also investigated. Results show significant differences in the progress of mushy zone and macrosegregation pattern between the present analysis and conventional analysis without filling effect.

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