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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.
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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