Mold Filling Simulation Using MARS Method for Thin Castings

Abstract

  The VOF (Volume of Fluid) method is adopted by most of the software used for the calculation of the interface, which consists of molten metal and air, during mold filling simulation. Since conventional cell volume fraction (F value) approaches apply the DA (Donor-Acceptor) procedure for the transport of fluid-segments, the interface slope cannot be transported with sufficient accuracy. On the other hand, the MARS (Multi-interface Advection and Reconstruction Solver) method developed by Kunugi has great advantages in terms of the accuracy to estimate the interface shape and quantity of advection. While the original software TopCAST™ applies the Porous-Media element, the MARS method simulates the mold filling behavior of thin-thickness castings. In mold filling analysis applying MARS, the capture shape of the free surface was found to improve during mold filling. It was also shown that it is very important to consider the surface tension in order to obtain reasonably accurate results. Furthermore, simulation performance such as CPU time and memory required were sufficient, confirming that the MARS method has adequate accuracy and functions for mold filling simulation.