Modeling Shot Sleeves and Ladle Pours
FLOW-3D Cast's General Moving Object model, the only one of its kind in commercial CFD software, allows users to model rigid body dynamics with six-degrees-of-freedom fully coupled with fluid flow. This fluid structure interaction model give casters a powerful tool, including the following capabilities:
- Users can evaluate the motion of multiple objects.
- There are no limitations on the geometry or range of motion.
- Objects can be allowed to move freely, or the user can prescribe the motion.
- Specified time-dependent thrust forces and torques can be applied to the objects.
- The range of motions includes motion around a fixed axis or point.
Below are examples of how FLOW-3D Cast's fluid structure interaction capabilities can be applied to casting design issues.
Ladle Pouring Simulation
This FLOW-3D Cast simulation shows temperature contours during metal
pouring process using a ladle. This is essential to accurately calculate filling
with precise foundry flow rate in the sprue and through the runner.
FLOW-3D Cast also captures accurate back pressure in the runner and sprue
system to match the foundry fill time.
Shot Sleeve Simulation
Shot sleeve driving fluid through the runners and gating system to
fill a tree structure of parts.
Ladle Pour and Shot Sleeve Simulation
A ladle filled with hot metal moves forward to fill a shot sleeve, and
then the motion of the shot sleeve drives the metal into a die.
Gravity Cast Ladle Pour
Simulation of a cylinder head for a 3.6L V6 engine, used in the Cadillac CTS
and Saturn Aura XR colored by defect concentration. It is cast with an A319
alloy using a semi-permanent mold process. The Air Entrainment and
Surface Defect models in FLOW-3D Cast were used to optimize the basin
and ladle design. Image courtesy of General Motors Powertrain.
Gravity Cast Example
A gravity casting example using FLOW-3D. A moving cup pours
the metal inside the mold, user for a realistic representation
of the casting process. Simulation results courtesy of Teksid.
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