Straightforward numerical analysis of casting process in a rectangular mold: From filling to solidification

To see the effect of filling on the solidification process, an attempt is m ade to study numerically the fluid flaw and heat transfer characteristics o f pure metal during mold filling and subsequent solidification process simu ltaneously in a rectangular mold. To analyze the fluid flow and heat transf er with free surface motion, the MAC method is employed in the SIMPLER algo rithm. Thermal stresses are also calculated based on temperature distributions thr ough finite element analysis. Results show the distinct difference between present analysis and conventional analysis which just deals with solidifica tion process only. Present analysis makes it possible to predict the defect s occurring during filling and solidification processes, since any section of a mold at any time can be examined without difficulty, which is very dif ficult in an experimental approach.