Numerical modeling of the solidification process in a mold-casting system with a gaseous gap

• Autorzy: Węgrzyn-Skrzypczak Ewa , Skrzypczak Tomasz , Sowa Leszek

Identyfikatory

DOI

10.17512/jamcm.2025.1.06

• Języki publikacji: EN

Abstrakty

EN

The paper focuses on the numerical modeling of the solidification process, with particular emphasis on the key physical phenomenon of heat transfer within the mold-casting system. This process is influenced by the presence of a gaseous gap, which introduces thermal resistance at the interface and affects the solidification rate. The numerical model is developed using the Finite Element Method (FEM), with separate spatial discretizations for both the casting and the mold. Additionally, the thermal expansion of these regions, caused by temperature-dependent volume changes, is accounted for. The model utilizes two distinct meshes to compute the evolving temperature fields. Heat exchange between the cast- ing and the mold is governed by boundary conditions linking the two regions. The solution is computed incrementally, with each region being solved independently at each time step. This paper describes the main assumptions of the mathematical and numerical models and presents the comparison of results of three simulation variants carried out using a custom- -built program.

Słowa kluczowe

EN

numerical modeling; finite element method; solidification process; heat transfer; gaseous gap

PL

modelowanie numeryczne; metoda elementów skończonych; proces krzepnięcia; przenoszenie ciepła; szczelina gazowa

• Wydawca: Wydawnictwo Politechniki Częstochowskiej
• Czasopismo: Journal of Applied Mathematics and Computational Mechanics
• Rocznik: 2025
• Tom: Vol. 24, nr 1
• Strony: 69--77
• Opis fizyczny: Bibliogr. 11 poz., rys., tab.

Twórcy

autor

Węgrzyn-Skrzypczak Ewa

• Department of Mathematics, Czestochowa University of Technology Czestochowa, Poland

autor

Skrzypczak Tomasz

• Department of Mechanics and Fundamentals of Machine Design, Czestochowa University of Technology, Czestochowa, Poland

autor

Sowa Leszek

• Department of Mechanics and Fundamentals of Machine Design, Czestochowa University of Technology, Czestochowa, Poland

Bibliografia

• [1] Suliga, M., Szota, P., & Mróz, S. (2017). Simulation and measurement of temperature in high speed drawing process of steel wires. Computer Methods in Materials Science, 17(1), 69-75. DOI: 10.7494/cmms.2017.1.0577.
• [2] Nishida, Y., Droste, W., & Engler, S. (1986). The air-gap formation process at the casting-mold interface and the heat transfer mechanism through the gap. Metallurgical Transactions B, 17, 833-844.
• [3] Florio, B.J., Vynnycky, M., Mitchell, S.L., & O’Brien, S.B.G. (2015). Mould-taper asymptotics and air gap formation in continuous casting. Applied Mathematics and Computation, 268, 1122-1139. DOI: 10.1016/j.amc.2015.07.011.
• [4] Mortensen, D., Henriksen, B.R., M’Hamdi, M., & Fjær, H.G. (2016). Coupled modelling of air-gap formation and surface exudation during extrusion ingot DC-casting. in: Grandfield, J.F., Eskin, D.G. (eds). Essential Readings in Light Metals. Springer, Cham. DOI: 10.1007/978-3-31948228-6_101.
• [5] Zeng, Y.D., Yao, Q.H., & Wang, X. (2017). The effect of air gap between casting and watercooled mold on interface heat transfer coefficient. Materials Science Forum, 893, 174-180, DOI: 10.4028/www.scientific.net/MSF.893.174.
• [6] Ahmadein, M., Pustal, B., Wolff, N., & Bührig-Polaczek, A. (2017). Determination and verification of the gap dependent heat transfer coefficient during permanent mold casting of A356 aluminum alloy. Material Science & Engineering Technology, 48(12), 1249-1256, DOI: 10.1002/mawe.201 700153.
• [7] Xu, J., Kang, J., Zheng, L., Mao, W., & Wang, J. (2022). Numerical simulation of the directional solidification process with multi-shell mold being gradually immersed in water. Journal of Materials Research and Technology, 19, 2705-2716. DOI: 10.1016/j.jmrt.2022.06.037.
• [8] Li, W., Li, L., Geng, Y., Zang, X., Jing, Y., Li, D., & Thomas, B.G. (2021). Air gap measurement during steel-ingot casting and its effect on interfacial heat transfer. Metallurgical and Materials Transactions B, 52, 2224-2238. DOI: 10.1007/s11663-021-02152-3.
• [9] Gowsalya, L.A., & Afshan, M.E. (2021). Heat transfer studies on solidification of casting process. in: Casting Processes and Modelling of Metallic Materials. DOI: 10.5772/intechopen.95371.
• [10] Węgrzyn-Skrzypczak, E., & Skrzypczak, T. (2024). Numerical modeling of the casting solidification process in a mold taking into account the influence of an air gap with variable width. Journal of Applied Mathematics and Computational Mechanics, 23(2), 117-128. DOI: 10.17512/ jamcm.2024.2.10.
• [11] Ablaoui, El M., Malendowski, M., Szymkuc, W., & Pozorski, Z. (2023). Determination of thermal properties of mineral wool required for the safety analysis of sandwich panels subjected to fire loads. Materials, 16(17), 5852-1 – 5852-18. DOI: 10.3390/ma16175852.

Uwagi

Opracowanie rekordu ze środków MNiSW, umowa nr POPUL/SP/0154/2024/02 w ramach programu "Społeczna odpowiedzialność nauki II" - moduł: Popularyzacja nauki (2025).