Numerical Modeling of Basic Physical Phenomena During the Creation Process of Casting-Riser System
L. Sowa
Department of Mechanics and Machine Design Fundamentals, Częstochowa University of Technology, 42-201 Częstochowa, Poland
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The work concerns the use of differential equations to modeling the process of manufacturing machine parts by a casting method. Making a casting with good strength properties is a difficult task and usually requires numerous computer simulations and their experimental verification at the prototyping stage. Computer simulations are then of priority importance in determining the appropriate parameters of the casting process and in selecting the dimensions of the riser for the casting fed with it. This requires complex mathematical and numerical models that take into account thermal, flow and contraction phenomena, but allow obtaining the results of numerical simulations effectively. The aim is to obtain a casting free from shrinkage defects. This type of research is still valid and requires continuous development. The paper presents the mathematical model and the results of numerical simulations of the casting creation process. The basic physical phenomena of the metal solidification process in the casting-riser system were modeled using the Finite Element Method (FEM). A partial differential equation describing the course of thermal phenomena in the process of 3D casting creation was applied. This equation was supplemented with appropriate boundary and initial conditions that define the physical problem under consideration. In numerical simulations, by selecting the appropriate riser, an attempt was made to obtain a casting without internal defects, using a simple method of identifying their location. This is the main aim of the research as such defects in the casting disqualify it from use.

DOI:10.12693/APhysPolA.139.602
topics: solidification, numerical simulations, heat transfer, FEM