Advanced Sand Casting Simulation using VoF based CFD Modelling in OpenFOAM

Course Description

Fluid flow is a complex phenomenon which involves the transport of mass momentum, energy and species under the influence of the velocity, pressure gradients, thermal effects and external sources. The analysis becomes more challenging when the fluid exists in the different phases and there is a continuous interaction between the phases through their interface where the mass, momentum and energy can be exchanged. Such flows are referred to as Multiphase flows.

Special numerical techniques are required to analyze these complex phase interaction in multiphase flows. CFD (Computational fluid Dynamics) provides a numerical framework for modelling these complex flow phenomenon by solving conservation equations at computational level. By CFD we can understand the physics involved in the flow process and optimize the flow behavior by modifying the operating conditions, material properties and geometry before conducting the actual physical process.

Sand casting is one of the most widely used manufacturing processes for producing metal components due to its cost-effectiveness, versatility, and ability to manufacture components of various sizes and complexities. Sand casting process is a type of multiphase flow in which molten metal poured into a mold cavity displaces the preoccupied air inside the cavity to the surrounding mould which is eventually vented out through the pores of the solid sand mould to the atmosphere. The casting process is also a practical example of multiregion process in which the cavity and the sand mould interact through the internal boundary by momentum and heat transfer during filling and solidification.

In this course we will develop a CFD workflow for simulating sand casting process using Openfoam an opensource software. We will investigate the underlying flow physics, analyze the parameters that influence the casting process and predicts the defects that could possibly occur such as incomplete filling, air entrapment, cold shut etc. Ultimately, this course aims to demonstrate how a real-world sand casting process can be transformed into a virtual CFD model, allowing engineers to understand, predict, and optimise casting performance before committing to physical production.

Meet the Instructors

Key Information:

• Duration: 3h 46m
• Level: beginner
• Language: English
• Access Period: 6 months of full access
• Category: OpenFOAM
• Instructor:Rakesh T V

Ratings and Reviews