Modeling of centrifugal casting processes with complex geometries

N.J. Humphreys, D. Mcbride, T. Croft, D.M. Shevchenko, Nicholas Green, M. Cross

Research output: Chapter in Book/Report/Conference proceedingChapter

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Abstract

Centrifugal casting offers a route to high quality products in difficult to cast high temperature low superheat alloys and thin section molds. Under centrifugal forces metal is forced into thin sections and can fill thicknesses of less than a millimeter. However, due to the high liquid metal velocities there is a high risk of surface turbulent flow and air entrainment within the liquid metal. The combination of interacting flow-thermal-solidification phenomena and associated defects is a challenging modeling task which the authors have previously described and validated. Capturing the metal-air interface, on what are inevitably complex three dimensional geometries, results in highly computationally expensive simulations and simulating a single cast can take weeks on a single processor. This contribution reports on modeling a complex centrifugal cast, gas entrainment, bubble transport and solidification, employing meshes of up to a million elements and investigates the scalability of the model on high performance clusters.
Original languageEnglish
Title of host publicationCFD Modeling and Simulation in Materials Processing
EditorsLaurentiu Nastac, Lifeng Zhang, Brian G. Thomas, Adrian Sabau, Nagy El-Kaddah, Adam C. Powell, Hervé Combeau
Place of Publication Hoboken, NJ, USA
PublisherJohn Wiley & Sons
Pages187-196
Number of pages10
ISBN (Electronic)9781118364697
ISBN (Print)9781118296158
DOIs
Publication statusPublished - 15 May 2012

Keywords

  • Computational Modeling
  • Centrifugal Casting
  • Free-surface flows
  • Air entrainment
  • Exhibitions
  • Liquid metals
  • Solidification
  • Centrifugation
  • Computer simulation

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