NUMERICAL METHOD FOR CALCULATION OF COMPLETE CASTING PROCESSES-PART I: THEORY

This article presents a method for calculation of the complete casting process, including the pouring of the liquid metal into the mold, its solidification, the deformation of the solidified cast, the formation of airgaps between the cast and the mold and their influence on the heat transfer, and the residual stresses. An original phase-change procedure is developed, valid for an arbitrary number of pure metals and/or alloys. A collocated version of a segregated finite-volume method is used to calculate both the liquid metal flow and the deformations and stresses in solids.