New numerical algorithm of gas-liquid two-phase flow considering characteristics of liquid metal during mold filling
(1. College of Materials Science and Engineering, Taiyuan University of Technology, Taiyuan 030024, China;
2. School of Metallurgical Engineering, Xi’ an University of Architecture & Technology, Xi’ an 710055, China;
3. College of Materials Science and Engineering, North University of China, Taiyuan 030051, China)
2. School of Metallurgical Engineering, Xi’ an University of Architecture & Technology, Xi’ an 710055, China;
3. College of Materials Science and Engineering, North University of China, Taiyuan 030051, China)
Abstract: A new program is developed for gas-liquid two-phase mold filling simulation in casting. The gas fluid, the superheated liquid metal and the liquid metal containing solid grains are assumed to be governed by Navier–Stokes equations and solved through Projection method. The Level set method is used to track the gas-liquid interface boundary. In order to demonstrate the correctness of this new program for simulation of gas-liquid two-phase mold filling in casting, a benchmark filling experiment is simulated (this benchmark test is designed by XU and the filling process is recorded by a 16-mm film camera). The simulated results agree very well with the experimental results, showing that this new program can be used to properly predicate the gas-liquid two-phase mold filling simulation in casting.
Key words: finite difference method; mold filling process; Projection method; Level set method; two-phase flow; numerical simulation