Abstract
Numerical simulation of casting filling process with complex shape is time-consuming. Compared with the traditional SOLA-VOF method, the lattice Boltzmann method (LBM) calculates the pressure field by particle distribution functions instead of the correction of the velocity and pressure fields, which greatly simplifies the calculation process. In addition, the LBM provides a flexible approach which can be easily parallelized. In this study, the LBM is employed to simulate casting filling process. An implementation of a volume-of-fluid (VOF) method within the lattice Boltzmann framework is proposed to capture the free surface of the casting filling process. A Smagorinsky large eddy simulation (LES) model is adopted to improve the numerical stability of the LBM. An adaptive time stepping technique is implemented to ensure an efficient and stable simulation. The model is validated by the experimental and simulation results of Campbell box filling process. The filling process of complex casting is simulated, and the result is compared with the filling process obtained by the SOLA-VOF method. The prediction accuracy and reliability of free surface profile is analysed.
Highlights
Casting process is an efficient manufacturing process, which can produce parts with complex shape
An unstable filling process is accompanied with turbulences, splashes, and bubbles, which leads to casting defects
Whether the lattice Boltzmann method (LBM) is capable of simulating the free surface flow with complex shape accurately remains to be investigated
Summary
Casting process is an efficient manufacturing process, which can produce parts with complex shape. Most simulation methods, such as SOLA-VOF method, the correction of velocity and pressure field is a time-consuming process Compared with these conventional methods, the lattice Boltzmann method (LBM) calculates the pressure field by particle distribution functions, which simplifies the calculation process. Ginzburg et al [1] proposed a generalized LBM model for free surface flow. Koerner et al [2] presented a LBM model for the simulation of metal foaming process, in which the free surface flow including gas diffusion is captured. Whether the LBM is capable of simulating the free surface flow with complex shape accurately remains to be investigated. In this study, the LBM coupled with volume-of-fluid method is employed to simulate the casting filling process.
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