Numerical Simulations Of Casting's Filling Process Based On A Projection Method

The simulation software of casting process plays an important role in making casting process, while the simulation results are accurate. But these software are mostly based on the single-phase flow model, which cannot predict the motion of gas-liquid interface accurately. So a method based on the multi-phase model is proposed. The new method can describe the motion of gas-liquid interface more accurately. At the same time, a new method based on the single-phase flow is developed.It is the first importance to describe the motion of gas-liquid interface, the Level Set method is used, and discreted with high order method. And a Particle method is added to the Level Set method to overcome the mass loss phenomenon when solute the motion with complex topological changes. To show the difference of the Level Set method and Particle Level Set method, a test of the Zalesak's sphere in the constant vorticity velocity field is made. There is also some research on the VOF method.The Projection method is used to solve the Navier-Stokes equation, which solve the pressure and the velocity separately and easy to apply the parallel program. To validate the method with a dam break test. The new Projection Level Set method to simulate the filling process of casting can reach a higher order result, and use less time comparing with the SOLA-VOF method.To evaluate the correctness of the Projection Level Set method, two examples are tested, one is the benchmark test, the other is the water flow test. With the simulation results, some improvement is made.Furthermore, two complex casting examples are tested, a track broken casting and a valve cover casting. From the results of the two casting filling examples, the capacity of the Projection Level Set method on complex casting examples can be evaluated.At last, for the SOLA-VOF method, the SOLA method is replaced by the Projection method. The new Projection VOF method which is based on the single-phase flow is developed. And some casting simulation testes are made, a benchmark test, a hydraulic bowl casting.