Numerical Simulation Of The Casting Process With Coupled Thermal And Mechanical Effects Based On ANSYS

In recent years, the numerical software used by casting enterprises are more and more,for example MAGMA and PROCAST. At present the main application of the softwaresimulation of liquid metal filling for eliminating the defects such as air hole or sandinclusion; simulation of solidification of castings during feeding, in order to eliminate theshrinkage and dispersed shrinkage defect. In addition, the casting solidification coolingafter hot cracking and deformation defects also have attention of the enterprise, the defectis mainly due to casting residual stress generated. Therefore on the solidification of castingthermal stress field numerical simulation is of great significance.This article proposed FEM/FEM casting process thermal stress fields duringsolidification of the two-way coupling numerical simulation method based on ANSYS.The method considered the casting/mold (core) system as a whole in the calculation, it canfully consider the mechanical boundary conditions. The contact element method was usedto study the interaction between the casting and the mold. The contact status was then fedback to the heat transfer analysis between the casting and the mold to re-evaluate the heattransfer coefficient based on the contact information. The thermal and mechanicalphenomena are then coupled in two directions.Select the typical castings stress frame as the research object, use the two-waycoupling method and the one-way coupling method to calculate it, and compare thesimulated results with the experimental data. The results show that, the temperaturedistribution calculated by two-way coupling method is more close to the experimentalresults. This paper use the two-way coupling method to simulate the train wheel castingthermal stress field, obtain satisfactory results, show that the two-way coupling method isalso suitable for the engineering application of parts of the thermal stress field simulation.