Abstract
Permanent molds incorporating active cooling systems are used widely in the casting of aluminium automotive components. There is a considerable potential for improving the productivity of the casting process in the casting shop by thermal modelling if it can be shown that the technique predicts accurately the history of temperature and heat flows in operating molds. A three-dimensional non-linear transient finite-element thermal analysis program has been developed to model the solidification sequence for metal castings. The program, which is capable of fully describing complex three-dimensional casting problems, has been used to simulate the thermal history of the permanent mold casting of an aluminium brake drum. The solidification sequence, total time to solidify, and mold temperature were studied in detail. The results predicted were verified with experimental data obtained from the actual casting.
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