3D computer simulation of melt flow and heat transfer in the lost foam casting process

A new mathematical model has been developed to simulate mould lling in the lost foam casting process, using the nite di erence method. The simulation of molten ow and track of free surfaces is based on the SOLA-VOF numerical technique. An algorithm was developed to calculate the gas pressure of the evaporated foam during the mould lling. The e ect of backpressure on the lling behaviour was modelled with an experimental function by adding three-dimensions 3DVOF functions. In order to verify the computational results, a thin grey iron plate was poured into a transparent mould. Cavity lling, foam depolymerization and gap formation were recorded with a 16mm high-speed camera. A good agreement was achieved for simulation results of lling sequences with those from experiments