FINDING THERMAL DISTRIBUTION IN THE CASTING OF AL-ALLOY BY SIMULATION USING FDM.

Abstract

The object is to get simulated observation of the solidification front movement inside casting, which was extracted from theoretical simulation of the solidification process, in the prediction of shrinkage cavities locations in the final ingots. A (Fortran) program was developed using the finite difference method. Several factors were taken into consideration in this system, such as the variation of liquid and solid volume fractions during solidification, changing the thermophysical properties of the cast metal with changing metal state and temperature. Also, the latent heat was introduced as an isolated source term to the mentioned equation. The verification of the system efficiency was achieved by the comparison between the cavity location in theoretical and real casting. There was a good agreement. Finally, the simulated cooling curves of selected points inside the casting were studied.