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

Mirbagheri, S. M. H ; Sharif University of Technology | 2004

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  1. Type of Document: Article
  2. DOI: 10.1016/j.apm.2004.03.007
  3. Publisher: 2004
  4. Abstract:
  5. 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 wall-slip 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. © 2004 Elsevier Inc. All rights reserved
  6. Keywords:
  7. ASOLA-VOF technique ; Coating permeability ; Donor-acceptor cells ; Free surface simulation ; Photographic technique ; Relaxation factors
  8. Source: Applied Mathematical Modelling ; Volume 28, Issue 11 , 2004 , Pages 933-956 ; 0307904X (ISSN)
  9. URL: https://www.sciencedirect.com/science/article/pii/S0307904X04000381