Numerical Simulation Of Inclusion Movement During Liquid Metal Filling And Solidifying Process

In the practical casting production, the factors of the irrational pouting conditions and theinclusions mixed with the molten metal when pouting into castings often lead to seriousquality problems of pieces. Simply depending on producer's experience or the small-scaleexperiments before actual production, that is neither accurate nor wasteful of time andmaterials, and increasing the production costs.Through a mathematical model, this paper simulates the flow of liquid metal and themovement of inclusions mixed with the liquid metal pouting into castings in the fillingprocess. Applying the continuity equation, momentum equation, the particle motion equationsand the heat transfer equation of the fluid mechanics basic equation, we do some calculatingcorrelation for the mathematical model. The calculation way is the finite difference method,and it is using the solution of finite difference and fourth-order Runge-Kutta-Gill method todiscrete mathematical model. In this method, SMAC law of Euler's method is taken tocalculate the free surface fluid flow.Fortran programming language is used to calculate the flow state of liquid metal,inclusions' trajectory and solidification process when pouting. Through the procedures, weget the calculated data files, using the C language function graphic demonstration of the liquidmetal flow simulation process, inclusions' trajectory and final position. The results are thesame as those of hydraulic simulation experimental, which verifies the accuracy andreliability of the numerical simulation.The ultimate location and the trajectory of inclusions can be recognized by numericalsimulation in the filling and solidification process. With the different pouring speed, size anddensity of inclusion and pouring period, we will have the different trajectory and finalposition of inclusion. Through the forecast of the inclusion's trajectory and final position,designer may change the casting speed, casting system, etc, that to get the ideal castingquality, according to the liquid metal, the inclusion may contain and the different requirements of castings.Therefore, it is using the numerical simulation applied in casting process to forecast thedefects that may arise in molding process, taking appropriate measures to regulate the fillingprocess parameters and optimize the filling process, which is of extremely importance to thequality, implementation of energy-casting process is.