On Analytical Concepts of Novel Multi-Resolution Casting Simulations

Abstract

One of the crucial ingredients of today’s numerical simulation technologies is their cross-scale and cross-platform capabilities for material processes applications. Handling of simultaneous evolution paths at various scales\ imes (i.e., multi-scaling) during complex material processes where materials microstructure & microchemistry interact with meso and macro events, is one of awkward challenges of computational material engineering. The material phase change and also its thermal energy evolutions are also drastically increasing the complexity of the numerical simulations. The introduction of multi-resolution and multi-scale numerical schemes in recent years and their ground-breaking potentials for computational material science applications have vividly raised the expectations for more resourceful future virtual tools. A crucial point in implementing these novel numerical techniques for simulation of material processes is their flexibility towards the modelling approach (i.e., discrete, continuous…) and also their compatibility with solver-independent platforms. As these multi-resolution\\physical techniques should provide some answers to the best ways of designing future high-performance materials along with optimisation of new & existing material processes and also improvement of their life-time performance, a broad & well-structured research work is required. Hence, the proposed multi-resolution framework herein, has been developed based on analytical & numerical techniques built on sound physical and mathematical foundations developed during the last few decades. The combination of recently developed concepts of dynamic\\evolving domains along with cross-scale grid overlapping\\interfacing and also sound parallel computing routines have been employed to address the multi-scale challenges of material processes simulations. In the research work herein, analytical and computational aspects of multi-resolution simulation framework for dynamic casting processes (i.e., continuous and semi-continuous casting) are presented and physical\\mathematical basis of the analytical-computational solidification and cooling modules are elaborated. Industrial applications of the techniques are also envisaged using parallel-processing and fast computing facilities for full-scale casting applications.