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Thermomechanics of the cooling stage in casting processes: Three-dimensional finite element analysis and experimental validation

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Abstract

A thermomechanical three-dimensional (3-D) finite element analysis of solidification is presented. The heat transfer model is based on a multidomain analysis accounting for noncoincident meshes for the cast part and the different mold components. In each subdomain, a preconditioned conjugate gradient solver is used. The mechanical analysis assumes the mold is rigid. A thermoelastic-viscoplastic rheological model is used to compute the constrained shrinkage of the part, resulting in an effective local air gap width computation. At each time increment, a weak coupling of the heat transfer and mechanical analyses is performed. Comparisons of experimental measurements and model predictions are given in the case of a hollow cylindrical aluminum alloy part, showing a good quantitative agreement. An application to an industrial aluminum casting is presented, illustrating the practical interest of thermomechanical computations in solidification analysis.

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Authors and Affiliations

  1. CEMEF-Materials Forming Center, Ecole des Mines de Paris, 06904, Sophia Antipolis, Cedex, France

    M. Bellet, F. Bay & J. -L. Chenot

  2. The Commissariat à l’Energie Atomique, 91680, Bruyèresle-Chatel, France

    F. Decultieux

  3. The Transvalor Company, 06904, Sophia Antipolis, Cedex, France

    M. Ménaï

  4. Materials Center, Ecole des Mines d’Albi-Carmaux, 81013, Albi, France

    C. Levaillant

  5. Volvo Company, 40508, Göteborg, Sweden

    P. Schmidt

  6. The Royal Institute of Technology, 10044, Stockholm, Sweden

    I. L. Svensson

Authors
  1. M. Bellet
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  2. F. Decultieux
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  3. M. Ménaï
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  4. F. Bay
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  5. C. Levaillant
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  6. J. -L. Chenot
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  7. P. Schmidt
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  8. I. L. Svensson
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Additional information

F. DECULTIEUX, Postdoctoral Student, formerly with the CEMEF-Materials Forming Center, Ecole des Mines de Paris

M. MÉNAÏ, Doctor, formerly with the CEMEF-Materials Forming Center, Ecole des Mines de Paris

C. LEVAILLANT, Doctor, formerly with the CEMEF-Materials Forming Center, Ecole des Mines de Paris

P. SCHMIDT, Doctor, formerly with the Royal Institute of Technology

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Bellet, M., Decultieux, F., Ménaï, M. et al. Thermomechanics of the cooling stage in casting processes: Three-dimensional finite element analysis and experimental validation. Metall Mater Trans B 27, 81–99 (1996). https://doi.org/10.1007/BF02915080

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  • DOI: https://doi.org/10.1007/BF02915080

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