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Abstract
This paper presents a finite element model for the three-dimensional simulation of industrial mold filling and solidification problems. The finite element solutions of mold filling problems involve highly convective fluid flow coupled with free surface, heat transfer, nonconstant material properties, and complex three-dimensional geometries. They present unusual challenges for both the finite element modeling and numerical solution algorithms. In this work a segregated algorithm is proposed to solve Navier-Stokes, energy, and front tracking equations. The streamline upwind Petrov-Galerkin formulation is used to obtain stable solutions. The position of the free surface is modeled using a level-set approach. The whole procedure is shown to present the accuracy, robustness, and cost-effectiveness needed for complex three-dimensional industrial applications.