Many diverse areas of industry benefit from the use of volume of fluid methods to predict the movement of materials. Casting is a common method of part fabrication. The accurate prediction of the casting process is pivotal to industry. Mold design and casting is currently considered an art by industry. It typically involves many trial mold designs, and the rejection of defective parts is costly. Failure of cast parts, because residual stresses reduce the part`s strength, can be catastrophic. Cast parts should have precise geometric details that reduce or eliminate the need for machining after casting. Volume of fluid codes will help designers predict how the molten metal fills a mold and where ay trapped voids remain. Prediction of defects due to thermal contraction or expansion will eliminate defective, trial mold designs and speed the parts to market with fewer rejections. Increasing the predictability and therefore the accuracy of the casting process will reduce the art that is involved in mold design and parts casting. Here, recent enhancements to multidimensional volume-tracking algorithms are presented. Illustrations in two dimensions are given. The improvements include new, local algorithms for interface normal constructions and a new full remapping algorithm for time integration. These methods are used on structured and unstructured grids.
The Moment-of-Fluid interface reconstruction technique is implemented in a second order accurate, unstructured finite element variable density incompressible Navier-Stokes solver. For flows with multiple materials, MOF significantly outperforms existing first and second order interface reconstruction techniques. For two material flows, the performance of MOF is similar to other interface reconstruction techniques. For strongly driven bouyant flows, the errors in the flow solution dominate and all the interface reconstruction techniques perform similarly.
Date: January 1, 2009
Creator: Garimella, R V; Schofield, S P; Lowrie, R B; Swartz, B K; Christon, M A & Dyadechko, V