An ALE‐FEM approach to the thermomechanics of solidification processes with application to the prediction of pipe shrinkage

Abstract

Purpose

The present paper addresses the computer modelling of pipe formation in metal castings.

Design/methodology/approach

As a preliminary, a brief review of the current state‐of‐the‐art in pipe shrinkage computation is presented. Then, in first part, the constitutive equations that have to be considered in thermomechanical computations are presented, followed by the main lines of the mechanical finite element resolution. A detailed presentation of an original arbitrary Lagrangian‐Eulerian (ALE) formulation is given, explaining the connection between the Lagrangian and the quasi Eulerian zones, and the treatment of free surfaces.

Findings

Whereas most existing methods are based on thermal considerations only, it is demonstrated in the current paper that this typical evolution of the free surface, originated by shrinkage at solidification front and compensating feeding liquid flow, can be effectively approached by a thermomechanical finite element analysis.

Research limitations/implications

Future work should deal with the following points: identification of thermo‐physical and rheological data, automatic and adaptive mesh refinement, calculation of the coupled deformation of mold components, development of a two‐phase solid/liquid formulation.

Practical implications

An example of industrial application is given. The proposed method has been implemented in the commercial software THERCAST^® dedicated to casting simulation.

Originality/value

The proposed numerical methods provide a comprehensive approach, capable of modelling concurrently all the main phenomena participating in pipe formation.

Citation

Bellet, M., Jaouen, O. and Poitrault, I. (2005), "An ALE‐FEM approach to the thermomechanics of solidification processes with application to the prediction of pipe shrinkage", International Journal of Numerical Methods for Heat & Fluid Flow, Vol. 15 No. 2, pp. 120-142. https://doi.org/10.1108/09615530510578410