A finite element simulation of metal flow in moulds

Abstract

Abstract Numerical tools for simulating the casting process are employed in an increasing manner by foundry engineers in order to understand and improve casting techniques. The correct simulation of metal flow and temperature profiles during filling is an important part of an overall numerical simulation kit which includes solidification and residual stress evaluations. In this study, we develop a two‐dimensional finite element model for studying metal flow and temperature fields during filling of mould cavities. A proper choice of turbulent/laminar model, correct tracking of metal free surface and evaluation of temperature to include metal‐air‐sand interaction are some of the essential features of the model.