Bilal Masood

Supervisor Zhe Tan

1. Simulate the uphill teeming process using two CFD softwares:

} ANSYS Fluent 13.0 } COMSOL Multyphysics 4.1

2. Study the effect of mould geometry and velocity of molten metal on the flow pattern inside the uphill teeming process.

1. Geometry 2. Meshing 3. Set up 4. Solution 5. Results

Velocity : 0.3 , 0.7 and 1.1 m/s Flaring angle : 0 , 6 , 12 and 18

1. Creating 3D Geometry in ANSYS DesignModeler

2. Meshing : Meshing the geometry in ANSYS Meshing aplication Creating named selections for the geometry boundaries

Flaring angle No. of nodes No. of elements

0 12543 55282 6 12419 54687

12 12091 53075 18 11917 52226

3. Set up: CFD Simulation set up in ANSYS Fluent

General set up: Solver type : Pressure-Based Time : Steady Gravity (y-direction): -9.81 m/s2

Model: Energy Equation Viscous Model k

3. Set up : Set Up the CFD Simulation in ANSYS Fluent

Materials: Fluid Molten Steel

Material property Value Unit Density 7010 Kg/m3 Viscosity 0.006 N s/m2 Heat capacity (Cp) 750 j/kg k Thermal conductivity (k) 41 W/m k

Boundary Conditions: velocity-inlet Velocity magnitude : 0.3, 0.7, 1.1 m/s Thermal : 1900 K Velocity-outlet Gauge pressure : 0 Pa Thermal : 1800 K Symmetry

4. Solution: Calculation running

5. Results Displaying results in ANSYS CFD-Post

5. Results Displaying results in ANSYS CFD-Post Flaring angle = 0

Flaring angle = 6

Flaring angle = 12

Flaring angle = 18

Simulating uphill teaming using COMSOL 4.1

3D 2D

Simulation type

2D SIMULATION

Geometry

Physics

Material

Study

Results

Solid edge ST

Turbulent flow

Heat Transfer

Mesh

Stationary

Liquid Steel

3D SIMULATION

Geometry

Physics

Material

Study

Results

Solid edge ST

Turbulent flow

Mesh

Stationary

Liquid Steel

Material

2D 3D

Turbulent flow

Turbulent flow

Heat Transfer

Physical model

Incompressible k

Initial Values P=0

U=0

Inlet

Velocities 0.3 0.7 1.1

Outlet P=0

Physical model

Initial Values

Inlet

Outlet

Incompressible k

P=0 U=0

Velocities 0.3 0.7 1.1

P=0

Initial Values

Temperature

Convective cooling

1800K

1900K

h=5

3D 2D

Angle Variation

0 6

12 18

2D 3D

Stationary Time Dependent Stationary

Solved Not Solved Solved Not

Solved

Time Dependent

6 Degree 18 Degree

Results 3D 6 Degree 18 Degree

12 Degree

Conclusion

For the all angles and the velocities the best results obtained are from the 6 degree angle 0.7 velocity. Hence it will help to improve the mechanical properties of the casted parts.This velocity of fluid contains very less number of the eddies and fine temperature distribution in the mold .Hence angle 6 degree with the 0.7 m/s velocity is recommended.

Comparison of the ANSYS and COMSOL

By looking at both results obtained from the two software ANSYS Fluent and COMSOL Multiphysics, it can be realized that the best design of the mold is with 6 degrees flaring with different velocities especially 0.7 m/s which give the best velocity distribution and less vortices

THANKS