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Research Papers: Conduction

On the Numerical Modeling of the Thermomechanical Contact for Metal Casting Analysis

[+] Author and Article Information
Michele Chiumenti

 Universidad Politécnica de Cataluña (UPC), Modulo C1, Campus Norte, C∕Gran Capitán s∕n, 08034 Barcelona, Spainmichele@cimne.upc.edu

Carlos Agelet de Saracibar, Miguel Cervera

 Universidad Politécnica de Cataluña (UPC), Modulo C1, Campus Norte, C∕Gran Capitán s∕n, 08034 Barcelona, Spain

J. Heat Transfer 130(6), 061301 (Apr 23, 2008) (10 pages) doi:10.1115/1.2897923 History: Received February 06, 2007; Revised January 25, 2008; Published April 23, 2008

The paper shows the intrinsic difficulties found in the numerical simulation of industrial casting processes using finite element (FE) analysis. Up until now, uncoupled pure thermal simulations have been mostly considered to model solidification and cooling phenomena. However, a fully coupled thermomechanical analysis provides a more complete insight of the casting process and the final outcome regarding the quality of the part. In this type of analysis, the thermomechanical model used plays a role of paramount importance, as the problem is coupled both ways through contact between part and mould. The paper presents the full statement of the problem regarding contact, and it considers the difficulties associated with FE mesh generation and time integration strategy. It also reviews soft and hard algorithms for mechanical contact presenting some new alternatives. Evaluation of coefficients used for thermal contact is also discussed, and a new proposal is presented. Finally, some numerical applications are presented to assess the performance of the proposed strategies both in benchmark and industrial problems.

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Copyright © 2008 by American Society of Mechanical Engineers
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Figures

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Figure 1

Sand gravity casting; CAD geometry of the foundry system

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Figure 2

HP die-casting process: CAD geometry and FE mesh generated

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Figure 3

Thermal contact model. (a) The heat conduction coefficient is a function of the effective contact area, which depends on the contact pressure. (b) Depending on the casting shrinkage, thermal conduction or thermal convection must be considered.

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Figure 4

Automotive part; FE mesh generated for the casting and the cooling system

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Figure 5

Contact benchmark: (a) fine mesh and (b) coarse mesh

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Figure 6

Contact reaction for both the penalty and the augmented Lagrangian methods when increasing the penalty parameter: (a) fine mesh and (b) coarse mesh

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Figure 7

Contact benchmarkcomparison between penalty and the augmented Lagrangian methods: (a) convergence of the contact penetration to satisfy contact impenetrability constraint when increasing the penalty parameter and (b) CPU time

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Figure 8

Cylindrical aluminum solidification test; geometry of the experimental apparatus and location of both thermocouple and displacement transductors

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Figure 9

Cylindrical aluminum solidification test; temperature evolution: (a) 10s, (b) 20s, (c) 40s, and (d) 90s

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Figure 10

Comparison between computed and experimental values of the temperature at the casting center, casting surface, and mould surface, respectively

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Figure 11

Comparison between computed and experimental values of the radial displacement on the casting surface and mould surface, respectively

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Figure 12

Temperature and shrinkage evolution (plane xy)

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Figure 13

(a) Temperature, (b) J2 von Mises, and (c) plastic strain distributions

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