Numerical Simulation of the Solidification Process with the Convective Movement of the Liquid Phase and the Formation of Shrinkage Cavity

T. Skrzypczak, E. Węgrzyn-Skrzypczak, L., L. Sowa Czestochowa University of Technology, 42-201 Czestochowa, Poland

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The presented work is devoted to the numerical modeling of the solidification process, taking into account the natural convection of the liquid phase as well as the shrinkage cavity formation process. The formation of the internal macroscopic cavities due to material shrinkage during the casting process is a frequent and serious concern that should be predicted numerically before the real process. In the paper, the main assumptions of the mathematical and numerical model are presented. The mathematical model is based on the partial differential equations of momentum, continuity, and heat transport with the convective term. The numerical description of the considered problem is based on the finite element method. The algorithm of the shrinkage cavity creation process is described. The influence of the motion of the liquid phase on the shape and localization of the shrinkage cavity is considered. Using the numerical model, an original computer program was developed. A computer simulation was done to obtain the temporary distributions of the temperature and velocity of the liquid phase in the casting, as well as the position and shape of the shrinkage cavity. The numerically obtained location and shape of the macroscopic defect were compared to the shrinkage cavity in the real casting.

DOI:10.12693/APhysPolA.142.129 topics: solidification, natural convection, shrinkage cavity, finite element method