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Effect Of Mould Filling On Evolution Of Mushy Zone And Macrosegregation During Solidification

Electronic Theses of Indian Institute of Science

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Field Value
 
Title Effect Of Mould Filling On Evolution Of Mushy Zone And Macrosegregation During Solidification
 
Creator Pathak, Nitin
 
Subject Casting
Solidification - Modelling
Pure Metals - Solidification
Binary Alloy Solidification
Alloy Casting
Sand Casting
Mushy Zone
Mould Filling
Manufacturing Engineering
 
Description The primary focus of the present work is to model the entire casting process from filling stage to complete solidification. The model takes into consideration any phase change taking place during the filling process. An implicit volume of fluid (VOF) based algorithm has been employed for simulating free surface flows during the filling process and the model for solidification is based on a fixed-grid enthalpy-based control volume approach. Solidification modelling is coupled with VOF through User Defined Functions (UDF) developed in commercial fluid dynamics (CFD) code FLUENT
6.3.26. The developed model is applied for the simultaneous filling and solidification of pure metals and binary alloy systems to study the effects of filling process on the solidification characteristics, evolution of mushy zone and the final macrosegregation pattern in the casting. The numerical results of the present analysis are compared with the conventional analysis assuming the initial conditions to be a completely filled mould cavity with uniform temperature, solute concentration and quiescent melt inside the cavity. The effects of process parameters, namely the degree of superheat, cooling temperature and filling velocity etc. are also investigated. Results show significant differences on the evolution of mushy zone and macrosegregation between the present analysis and the conventional analysis. The application of present model to simulate three dimensional sand casting is also demonstrated. The three dimensional competetive effect of filling generated residual flow and the buoyancy-induced convective flow pattern cause significant difference in macrosegregation pattern in casting.
 
Contributor Dutta, Pradip
 
Date 2010-01-01T09:26:06Z
2010-01-01T09:26:06Z
2010-01-01T09:26:06Z
2009-02
 
Type Thesis
 
Identifier http://hdl.handle.net/2005/634
 
Language en_US
 
Relation G22964