Thermo-elasto–viscoplastic numerical model for metal casting processes

The finite element method is used to model the thermomechanical behaviour of ductile cast iron using metallic moulds. Heat conduction is assumed for the heat transfer analysis and an elasto-viscoplastic model is employed to predict the development of thermal stresses and strains. Special finite elements with coincident nodes are used to model the heat transfer and the mechanical contact at the metal–mould interface. The local heat transfer coefficient between the casting and the mould may be dependent on the air-gap formation. The latent heat evolution effect is modelled by the use of the enthalpy method. An iterative procedure is required to take into account the material and the contact non-linearity. A real casting has been modelled and numerical results are compared with the experimental measurements.