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Numerical Simulation of Liquid-Solid Conversion Affecting Flow Behavior During Casting Filling Process |
Liu CAO, Fei SUN( ), Tao CHEN, Zihao TENG, Yulong TANG, Dunming LIAO |
State Key Laboratory of Materials Processing and Die & Mould Technology, Huazhong University of Science and Technology, Wuhan 430074, China |
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Cite this article:
Liu CAO, Fei SUN, Tao CHEN, Zihao TENG, Yulong TANG, Dunming LIAO. Numerical Simulation of Liquid-Solid Conversion Affecting Flow Behavior During Casting Filling Process. Acta Metall Sin, 2017, 53(11): 1521-1531.
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Abstract Misrun and cold shut are common defects in casting productions, which could make surface accuracy of castings poorer, even leading to cracking and casting scraps in them. The formation process of misrun and cold shut is hard to be observed directly only by experiment measures, since casting filling process is in a state of high temperature flow inside mold. The key to predict the defects accurately is the way to handle the effect of liquid-solid conversion on flow behavior. On the basis of existing methods for treating liquid-solid conversion, a calculation model of mushy region flow behavior through measurement of solid-fraction is developed, which can effectively investigate the flow behavior of mushy region in different stages. Generally, the critical solid-fraction method is adopted for mushy region with high solid-fraction, in consideration of that only the speed of high solid-fraction region is supposed to be zero during casting filling process. The variable viscosity method is applied for mushy region with low solid-fraction, due to casting filling process being unlikely to form toothpaste-like flow. However, the porous medium drag-based model is used for mushy region with middle solid-fraction, because only the middle solid-fraction region can be equivalent to porous medium. Combining the above three methods, a flow-field calculation program considering the effect of liquid-solid conversion on flow behavior during casting filling process is developed, in which finite volume method (FVM) is included for discretization equations; the pressure implicit with splitting of operator (PISO) algorithm is added for coupling pressure and velocity; the volume of fluid (VOF) algorithm is also combined for interface tracking. An numerical simulation of water-filled S-shaped channel is performed in the case of taking no account of liquid-solid conversion, and the simulated results coincide better with the experimental results, which certifies for its accuracy as an adopted model. Since the bottom filling casting craft is commonly used in single-shape casting, a comparison between the calculated results obtained using other single models and those using this model at different control parameters, is needed. The better agreement between them indicates that this new model is appropriate for calculating the flow behavior in mushy region.
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Received: 15 March 2017
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Fund: Supported by New Century Excellent Talents in University (No.NCET-13-0229) and National Science & Technology Key Projects of Numerical Control (No.2012ZX04010-031) |
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