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 made to study numerically the fluid flow and heat transfer characteristics of pure metal during mold filling and subsequent solidification process simultaneously in a rectangular mold. To analyze the fluid flow and heat transfer with free surface motion, the MAC method is employed in the SIMPLER algorithm. Thermal stresses are also calculated based on temperature distributions through finite element analysis. Results show the distinct difference between present analysis and conventional analysis which just deals with solidification process only. Present analysis makes it possible to predict the defects occurring during filling and solidification processes, since any section of a mold at any time can be examined without difficulty, which is very difficult in an experimental approach.