7) Numerical simulation of casting solidification in

permanent metallic molds

T.R. Vijayaram, et al. (7 2005) have used the numerical simulation for
casting simulation to predict and eliminate the defects like shrinkage,
porosity and hot tears. The aim of their work was to optimize the
design parameters, better understand the temperature history of the
solidifying casting and hence to
identify the hot spot region with the aid of obtained time-temperature
contours. They concluded that if their recommendations were followed
a defect free product will be obtained. (8) have used the the numerical
simulation to predict the final dimensions and residual stresses in the
die casting while comparing the obtained results against experimental
measurements taken on productions castings. (9) B.G. THOMAS et al
have developed a two-dimensional mathematical model to predict
stress generation in static-cast steel ingots during thermal processing
with the objective of understanding the role of stress generation in the
formation of defects such as panel cracks. Daming XU et al (10) have
proposed a mathematical model for mold filling processes under
centrifugal force field conditions . They have first compared a sample
simulation with a benchmark plate casting and then they have made
the simulation for a thin section casting with a titanium alloy melt of
assumed viscosity of 1.2 and 12 mm2/s respectively. The conclusion
they have drawn is that the flow behavior of the filling melts are
basically similar to each other although the less viscous melt tends to
fill into the thin section casting cavity faster. Ludmil Drenchev et al (12)
have used the numerical simulation to discuss the some aspects of the
macrostructure management of centrifugally cast particle reinforced.
They have used a specially developed software product to analyze of
many
technological regimes for casting cylindrical sleeves of composite alloy.
Nannan Song et al (13) have simulated numerically the solidifcation
process of horizontal centrifugal casting coupled with eutectic carbides
segregation . The results showed that the outer layer has a \sandwich
shape" solid
fraction manner. Results also indicate that the segregation of eutectic
MC is quite severe during centrifugal casting
process. It forms four zones of different content of carbides in radial
direction. The simulated results of MC carbides segregation
phenomenon agree with the experimental observations . Song Nannan
et al (15) have simulated the core filling process of cast high speed
steel roll for ductile iron as a core material. They have determined
based on the simulated results the optimal core filling parameters and

predicted the temperature fields, predicted the defects and proposed a

method for eliminating the defects.
Doru M. Stefanescu (20) has made a review of the fundamentals of
solidification of iron-base materials and of the mathematical models
that describe them. Marcial Gonzalez et al (50) have developed a
computational simulation system for modeling the solidification
process in a continuous casting facility for steel slabs. The system
couples a module for solving the direct problem (the calculation of
temperatures in the steel strand) with an inverse analysis module that
was developed for evaluating the steel/mold heat fluxes from the
information provided by thermocouples installed in the continuous
casting mold copper plates. In order to cope with the non-uniqueness
of the inverse analysis, a priori information on the solution, based on
the consideration of the problem physics, is incorporated. The stability
of the system predictions are analyzed and the influence of the first
trial used to start the evaluation procedure is discussed. C. Cho a et al
have presented a finite element mesh management technique to
analyze thermal stress
distribution of mushy region including molten materials and solidifying
shell through termination and elimination of the finite elements
representing the molten materials on the element list. We considered
temperature-dependent material properties during simulation and
adopted hybrid FDM/FEM method for enhancing accuracy: We validated
the proposed technique by comparing with other methods. As results,
the proposed method is found to effectively simulate real-time casting
process.
Gerardine G. Botte et al. (52) have compared between the finite
difference method (FDM) and the control volume formulation (CVF). An
analysis of truncation errors for the two methods is presented
Two examples representing different physical situations are solved
using the methods. The FDM failed to conserve mass for a small
number of nodes when both boundary conditions include a derivative
term (i.e. either a Robin or Neumann type boundary condition) whereas
the CVF method did conserve mass for these cases. The FDM is more
accurate than the CVF for problems with interfaces between adjacent
regions. The CVF is (DX) order of accuracy for a Neumann type
boundary condition whereas the FDM is (DX)2 order. Seid Koric and
Brian G. Thomas have developed a thermo-mechanical model to
simulate the continuous casting of shaped sections, such as used for
steel thin slabs. A general form of the transient heat equation including
latent-heat from phase transformations such as solidification and other
temperature-dependent properties is solved numerically for the
temperature field history. The resulting thermal stresses are solved by
integrating the highly nonlinear thermo-elastic-viscoplastic contitutive
equations using a two-level method.

The procedure has been implemented into Abaqus, (Abaqus Inc., 2005)
using a user-defined subroutine (UMAT) to integrate the constitutive
equations at the local level (Koric, 2006). The model is validated both
with a semi-analytical solution from Weiner and Boley (Weiner, 1963)
as well as with an in-house finite element code CON2D (Li, 2004, Zhu,
1993) specialized in thermo-mechanical modeling of continuous
casting. The model is applied to simulate a 3D transverse section of
the thin slab caster with a funnel, known for a complex geometry, with
actual temperature dependant properties and realistic operating
conditions as it moves down the mold. It has provided new valuable
insights into a complex 3D mechanical state of transverse and axial
stress of the solidifying shell retracted by the funnel geometry. Liao
Dunming et al (54) have used the finite difference method to simulate
casting thermal stress. The simulation system was developed to
analyze temperature and stress fields during casting solidification
process.
F. Bonollo et al (55) have predicted the fluid dynamics and the thermal
field induced by semi solid casting of an automotive component using
the MAGMASOFT software package. Results are compared with the
experimental processing tests and with microstructural investigations.
J.W. Gao, C.Y. Wang (56) have used the finite volume method to
numerically model and investigate the solidification of functionally
graded materials by centrifugal casting_
Yi-tao YANG et al. (58) have done simulation analysis of thermal stress
during casting process of large-sized alloy steel ingot to quantitatively
analyze the main reasons of common crack in the surface of alloy steel
ingot with 5%Cr during production and to propose the direction of
improvement, a physical model system, which consisted of steel ingot
mold, casting, riser of heat insulation, slag layer, sprue pipe, and
runner, was primarily established by three-dimensional CAD software
and proposed a plan to decrease the stress. M. E Heerschap (59) has
integrated the casting simulation done by VIEWCAST and the finite
element simulation done by MSC. MARC in order to include the residual
stresses caused by casting in his finite element calculations.
P. Barral a et al. (60) have used the numerical simulation to study some
problems related to aluminium casting .Numerical simulation of the
behaviour of the electromagnetic casting (EMC) is being extensively
used to improve the design of new casters and to analyse the influence
of the casting parameters in the solidifying ingot, namely, casting
speed, ingot size, casting temperature, flow rate of cooling water and
so
on. Marco Aloe (61) has used the numerical simulation to study the
microstructure formation, mechanical properties and density variation
of cast iron and compared the results with industrial cases.
:

S.M. Afazov et al.(62) has used the finite element method to simulate
the FE prediction of residual stresses of investment casting in a
Bottom Core Vane component of an aero engine subjected to
equiaxed cooling using two FEM codes (ABAQUS and ProCAST). B. Ravi
(63) has put guidelines for effective impelementation and the best
practices for efficient use of casting simulation technology. K.O. Yu et al
(64) have used the FE thermal analysis and experimental results to
predict the microstructure , defects and chemistry variation of
investment cast, complex shaped, single crystal turbine airfoils,
65) Numerical Simulation of the Investment Casting Process
A. S. Sabau (65) has used the numerical simulation to determine the
alloy shrinkage factors and the casting dimensions for the casting of
aluminum alloy A356 in shell molds made of fused silica and a zircon
prime coat.
(67) has developed numerical simulation model for the horizontal
centrifugal pipe casting process was developed with the commercial
simulation package Flow3D. It considers - additionally to mass, energy
and momentum conservation equations and free surface tracking - the
fast radial and slower horizontal movement of the mold. The iron inflow
is not steady state but time dependent. Of special importance is the
friction between the liquid and the mold in connection with the
viscosity and turbulence of the iron. Experiments with the mold at
controlled revolution speeds were carried out using a high-speed
camera. From these experiments friction coefficients for the description
of the interaction between mold and melt were obtained. With the
simulation model, the influence of typical process parameters (e.g.
melts inflow, mold movement, melt temperature, cooling media) on
the wall thickness of the pipes can be studied