Casting Mold Filling Process And Solidification Process Simulation

Casting process simulation is the current hot research of materials processing field. Most current researches process do filling and solidification process simulation separately, and implemented on cast professional software. Temperature field results of mold filling process numerical analysis can not be used to predict the defects, which provide no practical value for engineering; numerical analysis of solidification process based on the assumption "moment of filling, temperature uniform", which can cause inaccurate results of the temperature field and stress field, and the shrinkage, thermal cracking defects predict will inaccurate too, especially heavy castings. Therefore, the study on the whole process of filling and solidification simulation on general simulation software has great significance to raise practical engineering level of casting numerical simulation.In this paper, discrete equations of filling and solidification process were studied.Using ANSYS Fluent software package coupled calculate temperature field and flow field of mold filling process and temperature field of solidification process, which consistent with the experimental results.Using ANSYS Mechanical module calculate temperature field, thermal stress calculation of casting process, and predict shrinkage, shrinkage and thermal cracking defects. The main work is as follows:1. Use FVM discrete control equations of mold filling process.2. Use FEM discrete control equations of solidification process.3. Studied setting method of boundary conditions, initial conditions, material properties, turbulence model in ANSYS Fluent, and coupled calculate temperature field and flow field of mold filling process and temperature field of solidification process.4. Studied setting method of boundary conditions, initial conditions, material properties, turbulence model in ANSYS Mechanical, and coupled calculate temperature field and flow field of mold filling process. And use Thermal elastic-plastic mechanical model, coupled calculated temperature field and temperature field.5. Comparied the process and results of FVM and FEM, and obtained conclusion that FVM is faster than FEM in flow field and temperature field calculation.6. Select the appropriate criterion to predict shrinkage, hot crack defects.