Two phase flow simulation of mould filling process by sharp interface boundary condition capturing method

Abstract

The authors present an efficient finite difference based semisharp interface level set method to simulate the liquid–gas two phase flow in the casting’s mould filling process. The phase interface is partially sharply tracked with the level set method. Both the metal liquid and the gas are treated as incompressible fluid flows and solved by a second order projection method. The authors preserve the surface tension induced pressure jump condition while numerically smearing out the viscosity coefficient jump condition. The pressure jump condition is properly treated with a boundary condition capturing method. This method allows accurately simulating the flow motion of two phases and the capillary effect while keeping highly computational efficiency. Numerical simulations are in good agreement with both theoretical and experimental results.

Keywords:

• Mould filling simulation
• Liquid–gas flow
• Back pressure
• Surface tension
• Projection method
• Boundary condition capturing method

This research was partially supported by the Natural Science Foundation of China (grant no. 50805056), the Basic Research Foundation for Chinese Central Universities (grant no. C2009Z022J), the State Major Science and Technology Special Project Funds for High-end Numerical Machine and Basic Manufacturing Equipment and the Natural Science Foundation of Hubei for Distinguished Young Scholars (grant no. 2008CDB302).

Notes

This paper is part of a special issue of papers selected from MCSP8, the 8th Pacific Rim Conference on Modeling of Casting and Solidification Processes