• Journal of the Korean Society for Precision Engineering
• /
• v.14 no.1
• /
• pp.126-141
• /
• 1997

The purpose of this research is to develope a FEM program for analyzing solidification processes of axisymmetric casting, considering phase changes and the contact between the metal and mold. Tempera- ture recovery method is employed fro considering the phase changes releasing the latent heat and the coin- cident node method is used for calculating the amount of heat transfer between the metal and mold. Tan- gent modulus algorithm is adopted for calculating flow stress and a gap element is employed for modeling the interface between the mold and metal in finding deformed shapes. In order to verify the developed program, axisymmetric aluminum and steel casting processes are simulated. Temperature distribution, phase front position, and shrinkage and porosity creation are compared with measurements, FIDAP results, and good agreements are examined.

• Transactions of the Korean Society of Mechanical Engineers
• /
• v.19 no.4
• /
• pp.1095-1101
• /
• 1995

Numerical analysis of vertical solidification process allowing solid-liquid density change is performed by a hybrid method between a winite volume method (FVM) and a finite element method (FEM). The investigation focuses on the influence of solid-liquid density change and cooling rates on the motion of solid-liquid interface, solidified mass fraction, temperatures and thermal stresses in the solid region. Due to the density change of pure aluminium, solid-liquid interface moves more slowly but the solidified mass fraction is larger. The cooling rate of the wall is shown to have a significant influence on the phase change heat transfer and thermal stresses, while the density change has a small influence on the motion of the interface, solidified mass fraction, temperature distributions and thermal stresses. As the cooling rate increases, the thermal stresses become higher at the early stage of a solidification process, but it has small influence on the final stresses as the steady state is reached.

• Proceedings of the Korean Society of Precision Engineering Conference
• /
• 2005.10a
• /
• pp.786-789
• /
• 2005

The proper parameters in a twin roll strip casting are important to obtain the stabilization of the Mg sheet. What is examined in this paper is the quantitative relationships of the important control parameters such as the roll speed, height of pool region, outlet size of nozzle, solidification profile and the final point of solidification in a twin roll strip casting Unsteady conservation equations were used for transport phenomena in the pool region of a twin roll strip casting in order to predict a velocity, temperature distributions of fields and a solidification process of molten magnesium. The energy equation of cooling roll Is solved simultaneously with the conservation equations of molten magnesium In order to consider the heat transfer through the cooling roil. The finite difference method (2-D) and the finite element method (2-D) are used in the analysis of pool region and cooling roil to reduce computing time and to improve the accuracy of calculation respectively.

• Proceedings of the KSME Conference
• /
• 2001.06d
• /
• pp.319-324
• /
• 2001

A finite element model for the process of squeeze casting for metal matrix composites (MMCs) in cylindrical mold is developed. The fluid flow and the heat transfer are the fundamental phenomena in the squeeze casing process. To describe heat transfer with solidification of molten aluminum, the energy equation in terms of temperature and enthalpy are applied to two dimensional axisymmetric model which is similar to the experimental system. And one dimensional flow model is employed to simulate the transient metal flow. The direct iteration technique was used to solve the resulting nonlinear algebraic equations. A computer program is developed to calculate the enthalpy, temperature and fluid velocity. Cooling curves and temperature distribution during infiltration and solidification are calculated for pure aluminum. The temperature is measured and recorded experimentally. At two points of the perform inside and one point of the mold outside, thermocouple wire are installed. The time-temperature data are compared with the calculated cooling curves. The experimental results show that the finite element model can estimate the solidification time and predict the cooling process.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.26 no.10
• /
• pp.2104-2113
• /
• 2002

A finite element model is developed for the process of squeeze casting of metal matrix composites (MMCs) in cylindrical molds. The fluid flow and the heat transit. are fundamental phenomena in squeeze casting. To describe heat transfer in the solidification of molten aluminum, the energy equation is written in terms of temperature and enthalpy are applied in an axisymmetric model which is similar to the experimental system. A one dimensional flow model simulates the transient metal flow. A direct iteration technique was used to solve the resulting nonlinear algebraic equations, using a computer program to calculate the enthalpy, temperature and fluid velocity. The cooling curves and temperature distribution during infiltration and solidification were calculated fer pure aluminum. Experimentally, the temperature was measured and recorded using thermocouple wire. The measured time-temperature data were compared with the calculated cooling curves. The resulting agreement shows that the finite element model can accurately estimate the solidification time and predict the cooling process.

• Journal of the Korean Society of Safety
• /
• v.27 no.4
• /
• pp.7-12
• /
• 2012

In this study, the solidification characteristics inside the AC7A casting material was analyzed using the numerical analysis method and was verified using the experimental method by the pre-heated temperature conditions of metal casting device. For the numerical analysis, "COMSOL Multiphysics", the commercial code based on the finite element analysis(FEA), was used in order to predict the thermal deformation of the AC7A casting material including temperature, displacement and stress distribution. Also, in order to verify the results calculated by the numerical analysis, the experiment for temperature measurement inside the AC7A casting material was performed using the K-type thermocouple under the same condition of numerical analysis method. In the numerical results, thermal deformation inside AC7A casting material was well-suited for manufacturing products when the pre-heated temperatures of the metal casting device was $250^{\circ}C$. When the results of the temperature distribution were experimentally measured and were compared with those of the numerical result, it appeared that there was some temperature difference because of the latent heat by phase change heat transfer. However, the result of cooling temperature and patterns were almost similar except for the latent heat interval. The solidification characteristics was closely related to the temperature difference between the surface and inside of the casting.

• Journal of computational fluids engineering
• /
• v.7 no.4
• /
• pp.1-7
• /
• 2002

The phase-change transformation processes are relevant in many engineering applications. In particular, this phenomenon plays an important role in the extraction and fabrication operations in the metallurgical industry. The control of the heat transfer and fluid flow patterns is important to achieve casting quality and competitive production times. In the present study, a simple finite-element algorithm is developed for solid-liquid phase change problems. Natural convection in the liquid phase due to the temperature dependency of water density is considered by a numerical model. The predictions are compared with measurements by the particle image velocimetry(PIV). to show that the calculation results are in good agreement with the experiment results.

• Korean Journal of Air-Conditioning and Refrigeration Engineering
• /
• v.5 no.2
• /
• pp.111-121
• /
• 1993

Double-diffusive convection during solidification process of the binary mixture was studied numerically. Enthalpy method and finite element method were implemented in the analysis. Calculation carried out for $R{\alpha}_T=10^3-10^4$ and $R{\alpha}_T=0-10^5$. The results show that the variation of thermal Rayleigh number changes the fields of velocity, temperature and concentration, but the variation of solutal Rayleigh number gives little effects on those. In conclusion, concentration gradient can be negligible compared with temperature gradient in macroscopic point of view, although concentration gradient plays a role in forming dendrite.

• Transactions of the Korean Society of Mechanical Engineers A
• /
• v.20 no.1
• /
• pp.189-205
• /
• 1996

The twin-roll type strip continuous casting process(or direct rolling process) of steel materials is characterized by two rotating water cooled rolls receiving a steady supply of molten metal which solidifies onto the rolls. A solidification analysis of molten metal considering phase transformation and thermofluid is performed using finite diffefence method with curvilinear coordinate to reduce computing time and molten region analysis with arbitrary shape. An enthalpy-specific heat method is used to determine the temperatures inthe roll and the steel. The temperature distribution of cooling roll is calculated using two dimensional finite element method, because of complex roll shape due to cooling hole in rolls and improvemnt accuracy of calculation result. The energy equaiton of cooling roll is solved simultanuously with the conservation equaiton of molten metal in order to consider heat transfer through the cooling roll. The calculated roll temperature is compared to experimental results and the heat transfer coefficient between cooling roll surface and rolling material(steel) is also determined from comparison of measured roll temperature and calculated temperature.

• Journal of the Korean Crystal Growth and Crystal Technology
• /
• v.6 no.1
• /
• pp.19-31
• /
• 1996

To invetigate the impurity distribution in GaAs crystal grown by horizontal Bridgman method, we constructd the mathematical model describing heat transfer, mass transfer and fluid flow n transient growth of GaAs. Galerkin finite element method and implicit time integration were used to solve the equations and simulate the transient growth. The concentration distribution is similar to the case of diffusion controlled growth when Gr - 0. With the increase of Gr the concentration profile is distroted and the minimum solute concentration appears near the interface. As solidification prosceeds, interface deflection increases steadily and transverse segregation increases until mixing by flow becomes steady. The axial segregation increases with solidification. But, with high intensity of flow axial segregation becomes steady after short transient. At small and large Gr the result showed a good agreememt with the prediction Smith and Scheil.