Three-Dimensional Numerical Simulation Of Mold Filling Process Of Casting

With the development of market economy, more requirements and efficiency of casting production have been put forward. However, because of long production cycle and high reject rate, the traditional technology design method could not meet with modern production requirements. The numerical simulation of mold filling process can not only give us an intuitionistic impression, but also take the exact temperature data to solidification process which may predict the formation of casting defects, assure casting quality, reduce trial production period and increase the competition ability of casting products. The numerical simulation of mold filling process takes an important role in numerical simulation of casting. The numerical simulation of mold filling process is also a difficult topic for its complexity.Based on momentum equation, energy equation and continuity equation, a three-dimensional simulation software has been developed. Traditional SOLA-VOF method has been taken to use in the software. Non-uniform mesh discretion which reflects the accuracy geometrical shape of original castings more closely has been adopted before the simulation. By transmuting formation of momentum equation, the iteration process has been divided into items with pressure and items without pressure. By this way, the iteration times have been reduced greatly and it makes the software meet with the speed requirement of practical engineering.Based on coupled momentum equation and energy equation, thesimulation of temperature field has been carried out. For the properties of liquid metal change a little in the filling process, linear interpolation has been adopted. By this way, the properties of liquid metal are not be adjusted until the end of each calculating step. It avoids the complicated iteration but not affects the accuracy of result. It makes the simulation of the complicated casting possible and provides an original temperature field for the simulation of solidification process.Experiments used water to fill transparent molds which are to simulate the filling process of practical castings have been done and the process have been kinescoped by high speed video. By comparing and analyzing the result, we are glad to see that the result is fit quite well. To test the simulation result of temperature field, we choose a practical model in the factory to measure inner temperature of the casting with thermal couples, and we also do a compare with the result of simulation. The result is fit for the practical measure quite well.A new software frame which shows a intuitionistic figure of the simulation result of the casting has been developed. The casting figure will be shown in the direction which you want to see. The software can also give the image of inner casting by subdivision.