Modeling simulation and experimental validation for mold filling process

Based on the continuum equation, momentum conservation and energy conservation equations, the numerical model of turbulent flow filling was introduced; the 3-D free surface vof method was improved. Whether or not the numerical simulation results are reasonable, it needs corresponding experimental validations. General experimental techniques for casting fluid flow process include: thermocouple tracking location method, hydraulic simulating method, heat-resistant glass window method and X-ray observation etc. The hydraulic analogue experiment with DPIV technique is arranged to validate the fluent flow program for low-pressure casting with 0.1×105 Pa and 0.6×105 Pa pressure visually. By comparing the flow head, liquid surface, flow velocity, it is found that the filling pressure value influences the flow state strongly. With the increase of the filling pressure, the fluid flow state becomes unstable, the flow head becomes higher, and the filling time is reduced. The simulated results are accordant with the observed results approximately, which can prove the reasonability of our numerical program for filling process further.