Abstract
The prediction of misruns is challenging because flow and solidification have to be computed in a strongly coupled manner. Effects of surface tension, wetting angle and reduced melt flow due to the solidification must be modeled with high precision.
To accomplish these requirements a finite-volume method with arbitrary polyhedral control volumes is used to solve flow and solidification in a strongly coupled manner. The Volume-of-Fluid approach is used to capture the phase separation between gas, melt and solid in connection with a High-Resolution Interface-Capturing scheme to gain sharp interfaces between phases. An additional source term in the momentum equation was implemented to model the resistance of the dendrite network to the melt flow.
This methodology was applied to predict misruns in thin walled aluminum sand and TiAl centrifugal investment castings. Validation against casting trials using simplified geometries is followed by successful prediction of misruns in complex industrial applications.
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Jakumeit, J., Subasic, E., Bünck, M. (2014). Prediction of Misruns in Thin Wall Castings Using Computational Simulation. In: Tiryakioğlu, M., Campbell, J., Byczynski, G. (eds) Shape Casting: 5th International Symposium 2014. Springer, Cham. https://doi.org/10.1007/978-3-319-48130-2_31
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DOI: https://doi.org/10.1007/978-3-319-48130-2_31
Publisher Name: Springer, Cham
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