Validation of Foundry Process for Aluminum Parts with Flow3d

The importance of smooth mould filling in the foundry casting process has been recognized for a long time. More uniform the filling process is, the better the quality of the casting of the products produced. Successful computer simulations can help to reduce the number of trials and cut down the lead time in the design of new casting products by better understanding the complex mechanisms and interplay of different process parameters in the mould filling process. This work deals with the numerical simulation of the filling of gravity die casting, lost foam casting and its solidification. Computations were carried out using Flow3D ® which is a general computational fluid dynamics (CFD) code [1]. The simulation involved viscous fluid flow with transient free surfaces, metal/mould heat transfer, conduction in both metal and mould, and latent heat release. Full Navier-Stokes equations, energy equations and Volume of Fluid (VOF) methods were used to simulate this topic. Simulations results were compared with experimental data and good correlation for thermal effects and front tracking evolution throughout the parts have been found. Introduction PSA Peugeot Citroën owns three foundries. They are located in northern France. The foundry of Charleville Mézières produces cylinder heads by gravity die casting, and lost Foam cylinder heads as well as GJS cast-iron parts. The Foundry of Mulhouse produces crankcases cylinders in high pressure die casting. Lastly the foundry of Sept-Fons produces crankcases cylinders and revolution parts in GJL Cast. For many years, PSA Peugeot Citroen has been using the numerical simulation in its projects development of new vehicles and new parts. The foundry was one of the first processes modelized. For twenty years, design and new part’s development of power units or crossmember parts were based on the numerical simulation of the foundry. Presently, the tools for simulation are impossible to circumvent from the numerical channel of design as well as the CAD.