Prediction of Solidification Behavior of Al Alloy in a Cube Mold Cavity
This paper focuses on the mathematical modeling for
solidification of Al alloy in a cube mold cavity to study the
solidification behavior of casting process. The parametric
investigation of solidification process inside the cavity was
performed by using computational solidification/melting model
coupled with Volume of fluid (VOF) model. The implicit filling
algorithm is used in this study to understand the overall process from
the filling stage to solidification in a model metal casting process.
The model is validated with past studied at same conditions. The
solidification process is analyzed by including the effect of pouring
velocity as well as natural convection from the wall and geometry of
the cavity. These studies show the possibility of various defects
during solidification process.
[1] I. T. Im, W. S. Kim and K. S. Lee, “A unified analysis of filling and
solidification in casting with natural convection,” International Journal
of Heat and Mass Transfer, Vol. 44, pp. 1507-1515, 2001.
[2] C. R. Swaminathan and V. R. Voller, “A General Enthalpy Method for
Modeling Solidification Process,” Metall Trans, Vol. 23B, pp. 651-664,
1992.
[3] Y. Chen, Y. T. Im and J. Yoo, “Finite element analysis of solidification
of aluminum with natural convection,”Journal of Materials Processing
Technology, Vol. 52, pp. 592- 609, 1995.
[4] C. R. Swaminathan and V. R. Voller, “A time-implicit filling
algorithm,”Appl. Appl. Math. Modelling, Vol. 18, pp. 101-108, 1994.
[5] N. Pathak,A. Kumar, A. Yadav and P. Dutta, “ Effects of mould filling
on evolution of the solid–liquid interface during solidification,” Applied
Thermal Engineering, Vol.29, pp. 3669–3678, 2009.
[6] W. M. A. Jadayil, “Studying the Effects of Varying the Pouring Rate on
the Casting Defects Using Nondestructive Testing Techniques,” Jordan
Journal ofMechanical and Industrial Engineering, Vol.5 pp. 521-526,
2011.
[7] D. Vander Boon, “Effects of Solidification Rate on Porosity Formation
and Cast Microstructure in Aluminum Alloy A356,” Laboratory Module
3 EGR 250 – Materials Science & Engineering, February 2005.
[8] D. Kakas, L. Kovacevic and T. Pal, “Improvement of casting process
control by computer simulation and experimental observation,”
Proceedings of the 3rd International Conference on Manufacturing
Engineering, Greece, October 1-3, 2008.
[9] V. Gopinath and N. Balanarasimman, “Effect of Solidification
Parameters on the Feeding Efficiency of Lm6 Aluminium Alloy
Casting,” IOSR Journal of Mechanical and Civil Engineering, Vol. 4,
Issue 2, PP. 32-38, 2012.
[10] C. J. Kim and M. Kaviany, “A fully implicit method for diffusioncontrolled
solidification of binary alloys,” Inr. J. Heat Mass Tranrfer,
Vol. 35, PP. 1143-l 154, 1992.
[11] M. A. Radyand A. K. Mohanty, “Natural convection during melting and
solidification ofpure metal in a cavity,” Numerical heat transfer, Vol. 29,
pp. 49-63, 1996.
[12] J. H. Kuo, R. J. Weng and W. S. Hwang, “Effects of Solid Fraction on
the Heat Transfer Coefficient at the Casting/Mold Interface for
Permanent Mold Casting of AZ91D Magnesium Alloy,” Materials
Transactions, Vol. 47, pp. 2547- 2554, 2006.
[13] K. Akihiko and K. Yasunori, “Mold Filling Simulation for Predicting
Gas Porosity,” H Engineering Review. Vol. 40, pp. 83-88, 2007.
[14] D. K. Nguyen and S. C. Huang, “Analysis the Effects of Turbulence
Flow, the Heat, and Phases Transfer on Thermal Arrest Time in Casting
Process by Computational Fluid Dynamic Method,” Journal of
Engineering Technology and Education, Vol. 9, pp. 436-450, 2012.
[15] A. B. Crowley and J. R. Ockedon, “On the Numerical Solution of an
Alloy Solidification Problem,” Int. J. heat Mass Transfer. Vol. 22, pp.
941-946, 1979.
[16] M. Mbayeand E. Bilgen, “phase change process by natural convection-
Diffusion in rectangular enclosure,” Heat and Mass Transfer Vol. 37, pp.
35-42, 2001.
[17] ANSYS, Release 14.0 UP20111024, Copyright 2011 SAS IP, Inc.
[1] I. T. Im, W. S. Kim and K. S. Lee, “A unified analysis of filling and
solidification in casting with natural convection,” International Journal
of Heat and Mass Transfer, Vol. 44, pp. 1507-1515, 2001.
[2] C. R. Swaminathan and V. R. Voller, “A General Enthalpy Method for
Modeling Solidification Process,” Metall Trans, Vol. 23B, pp. 651-664,
1992.
[3] Y. Chen, Y. T. Im and J. Yoo, “Finite element analysis of solidification
of aluminum with natural convection,”Journal of Materials Processing
Technology, Vol. 52, pp. 592- 609, 1995.
[4] C. R. Swaminathan and V. R. Voller, “A time-implicit filling
algorithm,”Appl. Appl. Math. Modelling, Vol. 18, pp. 101-108, 1994.
[5] N. Pathak,A. Kumar, A. Yadav and P. Dutta, “ Effects of mould filling
on evolution of the solid–liquid interface during solidification,” Applied
Thermal Engineering, Vol.29, pp. 3669–3678, 2009.
[6] W. M. A. Jadayil, “Studying the Effects of Varying the Pouring Rate on
the Casting Defects Using Nondestructive Testing Techniques,” Jordan
Journal ofMechanical and Industrial Engineering, Vol.5 pp. 521-526,
2011.
[7] D. Vander Boon, “Effects of Solidification Rate on Porosity Formation
and Cast Microstructure in Aluminum Alloy A356,” Laboratory Module
3 EGR 250 – Materials Science & Engineering, February 2005.
[8] D. Kakas, L. Kovacevic and T. Pal, “Improvement of casting process
control by computer simulation and experimental observation,”
Proceedings of the 3rd International Conference on Manufacturing
Engineering, Greece, October 1-3, 2008.
[9] V. Gopinath and N. Balanarasimman, “Effect of Solidification
Parameters on the Feeding Efficiency of Lm6 Aluminium Alloy
Casting,” IOSR Journal of Mechanical and Civil Engineering, Vol. 4,
Issue 2, PP. 32-38, 2012.
[10] C. J. Kim and M. Kaviany, “A fully implicit method for diffusioncontrolled
solidification of binary alloys,” Inr. J. Heat Mass Tranrfer,
Vol. 35, PP. 1143-l 154, 1992.
[11] M. A. Radyand A. K. Mohanty, “Natural convection during melting and
solidification ofpure metal in a cavity,” Numerical heat transfer, Vol. 29,
pp. 49-63, 1996.
[12] J. H. Kuo, R. J. Weng and W. S. Hwang, “Effects of Solid Fraction on
the Heat Transfer Coefficient at the Casting/Mold Interface for
Permanent Mold Casting of AZ91D Magnesium Alloy,” Materials
Transactions, Vol. 47, pp. 2547- 2554, 2006.
[13] K. Akihiko and K. Yasunori, “Mold Filling Simulation for Predicting
Gas Porosity,” H Engineering Review. Vol. 40, pp. 83-88, 2007.
[14] D. K. Nguyen and S. C. Huang, “Analysis the Effects of Turbulence
Flow, the Heat, and Phases Transfer on Thermal Arrest Time in Casting
Process by Computational Fluid Dynamic Method,” Journal of
Engineering Technology and Education, Vol. 9, pp. 436-450, 2012.
[15] A. B. Crowley and J. R. Ockedon, “On the Numerical Solution of an
Alloy Solidification Problem,” Int. J. heat Mass Transfer. Vol. 22, pp.
941-946, 1979.
[16] M. Mbayeand E. Bilgen, “phase change process by natural convection-
Diffusion in rectangular enclosure,” Heat and Mass Transfer Vol. 37, pp.
35-42, 2001.
[17] ANSYS, Release 14.0 UP20111024, Copyright 2011 SAS IP, Inc.
@article{"International Journal of Chemical, Materials and Biomolecular Sciences:71655", author = "N. P. Yadav and Deepti Verma", title = "Prediction of Solidification Behavior of Al Alloy in a Cube Mold Cavity", abstract = "This paper focuses on the mathematical modeling for
solidification of Al alloy in a cube mold cavity to study the
solidification behavior of casting process. The parametric
investigation of solidification process inside the cavity was
performed by using computational solidification/melting model
coupled with Volume of fluid (VOF) model. The implicit filling
algorithm is used in this study to understand the overall process from
the filling stage to solidification in a model metal casting process.
The model is validated with past studied at same conditions. The
solidification process is analyzed by including the effect of pouring
velocity as well as natural convection from the wall and geometry of
the cavity. These studies show the possibility of various defects
during solidification process.", keywords = "Buoyancy driven flow, natural convection driven
flow, residual flow, secondary flow, volume of fluid.", volume = "9", number = "12", pages = "1418-9", }
