Abstract
The aim of this work is the development of the lattice Boltzmann model for simulation of the mold filling process. The authors present a simplified approach to the modeling of liquid metal-gas flows with particular emphasis on the interactions between these phases. The boundary condition for momentum transfer of the moving free surface to the gaseous phase is shown. Simultaneously, the method for modeling influence of gas back pressure on a position and shape of the interfacial boundary is explained in details. The problem of the lattice Boltzmann method (LBM) stability is also analyzed. Since large differences in viscosity of both fluids are a source of the model instability, the so-called fractional step (FS) method allowing to improve the computation stability is applied. The presented solution is verified on the bases of the available reference data and the results of experiments. It is shown that the model describes properly such effects as: gas bubbles formation and air back pressure, accompanying liquid-gas flows in the casting mold. At the same time the proposed approach is easy to be implemented and characterized by a lower demand of operating memory as compared to typical LBM models of two-phase flows.
Highlights
It is currently estimated that even 90% of technological problems accompanying the casting production are related to not proper proceedings of a mold pouring
The obtained results indicate that the presented piston model describes properly interactions between fluids filling the casting mold for flows with the velocity range within the incompressible limits
This model correctly represents such phenomena as a gas bubble formation and gas back pressure effect which are of the essential meaning from the point of view of the casting practice
Summary
It is currently estimated that even 90% of technological problems accompanying the casting production are related to not proper proceedings of a mold pouring. Due to its complexity and multitude of effects accompanying this process, engineers designing casting technologies are more and more often using the simulation software These programs, regardless of their increasing popularity, are still characterized by a low efficiency. Some other interesting but more complicated models with multiple distribution functions for multiphase/multicomponent flows conjugated with heat transfer exists [23, 24] this work discusses the simplified numerical model of liquid-gas flows characterized by an adequate stability and accuracy, which will allow its application in simulations of the casting mold pouring process
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