Finite element analysis of turbulent flow during the mould filling in casting

Abstract : A finite element model for 2D and 3D incompressible turbulent hows has been developed to describe the filling stage of casting processes. The how is simulated by averaged Navier-Stokes equations and the standard k-epsilon model is used to take into account its turbulent behaviour. A simplified version of the wall function method is employed to approach the dominant viscous effects in the near wall zones. About the mechanical model, a mixed velocity-pressure Arbitrary Lagrangian Eulerian formulation has been developed to provide a natural representation of the moving free boundaries, by means of a convected mesh. The validation of our models is established from differents tests found in the literature. The capability of the software is illustrated with a casting-like flow of industrial complexity, in which turbulent effects are dominant.