LOST FOAM FILLING

LOST FOAM EXAMPLE WITH METAL SURFACE CONTAMINANT TRACKING

In this example the fluid flow is 2-D, but the heat flow occurs in all three directions.
Geometry components are adiabatic. A passive transportable scalar function is used to
track surface contamination produced due to foam decomposition by hot metal.

Set simulation units to SI-Celsius

1. Time controls
Finish time – 1 s.
Finish condition – None (finish time only)

2. Models
General Models
Gravity = 0
Viscous Flow
Turbulence – Laminar
Temp calculations - First order
Fluid to solid heat transfer – Uniform solid temperature

3. Casting Models
Enable surface defect tracking

4. Solidification
Activate Solidification model

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 5. Lost Foam
Activate Full lost foam model

6. Numerics
Pressure solver options
Manual compressibility – 1E-05
Time step control
Initial time step - 0.001
7. Meshing
Add new Mesh Box

Add grid lines in X direction at 0.00736, 0.01209, 0.02, 0.02469, 0.03677,

and 0.04709.
Also add grid lines in Z direction at 0.00246, 0.00514, 0.00633, 0.00867,
0.00955 and 0.0122.

8. Geometry
Component 1 (Foam)
Subcomponent 1
Name – Foam
Limiters – X low = 0

Default Mold (Mold)

(Disable/Delete Remaining space)
Subcomponent 2
Limiters – X low = 0.00736 X high = 0.01209
Z low = 0.00514 Z high = 0.0122

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 Subcomponent 3
Limiters – X low = 0.02 X high = 0.02469
Z low = 0.00246 Z high = 0.00955
Subcomponent 4
Cylinder – Outer radius = 0.0026
Transformation – Position X = 0.03677, Z = 0.01
Rotation X = 90
Subcomponent 5
Cylinder – Outer radius = 0.0026
Transformation – Position X = 0.0466, Z = 0.00492
Rotation X = 90

Subcomponent 6
Limiters – X high = 0.0001
Z high = 0.00643
Subcomponent 7
Limiters – X high = 0.0001
Z low = 0.00857

(Mesh planes and Mold subcomponents)

Component properties
Foam
Initial Temp = 65oC
Heat transfer mode = Uniformly Dynamic Temperature
Solid Properties
Density *Specific heat = 80000
Surface properties
Heat transfer to fluid 1= 6000
Foam parameters
Melting density transfer energy = 16000 Pa
Melting temperature = 100 oC
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 Vapor density transfer energy = 8000 Pa
Vaporization temperature = 747 oC

Default Mold
Initial temp = 25 oC
Heat transfer mode = Prescribed Temperature
Surface properties
Heat transfer to fluid 1= 10

9. Boundary conditions
Wall = XMAX, YMIN, YMAX, ZMAX, ZMIN
Temperature = 25oC
Heat transfer coefficient to metal = 10
Pressure = XMIN
Pressure = 7410 Pa
Temperature = 715 oC

10. Metal properties

Initial temp = 715 oC
Initial gas pressure = 0
Load from material database - Pure_Aluminium-Mills data

11. Heat transfer coefficient

Between Metal and Foam – 6000
Between Metal and Mold – 10

12. Output
Basic for output – Fill fraction
Selected data
Fluid temperature
Foam component volume fraction
Surface defect concentration

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