Proceedings of the 7th Pacific Rim International Conference on
Modeling of Casting and Solidification Processes
Dalian, China, August 19-22, 2007
RECENT DEVELOPMENT OF MODELING OF
CASTING AND SOLIDIFICATION PROCESSES
Edited by JIN Jun-ze, YAO Shan,
HAO Hai, WANG Tong-min
Proceedings of Modeling ofCasting and Solidification Processes W, 2007
Edited by JINJun-ze,et al.
Table of Contents
Preface
Organization
Keynotes
Recent development and challenges of CAE in castingltsuo Ohnaka, Akira Sugiyama, Jindong Zhu and Toshihiko Murakami 3
Development of an advanced rheo-diecasting technique based on H-NCM
CP. Hong and J,M. Kim 9
The role of as-cast porosity, stress and strain on hot tearing in direct chill cast AA5182
S.L. Cockcroft, A.B. Phillion, J. Mitchell, DM. Maijer and P.D. Lee 17
Experimental investigation of drop formation by ink jet printingHsinHung Chou, MingHsiu Tsai, Chi Wei Chou, WengSing Hwang and Hao-Long Chen 25
Spray forming and advanced materials
Qingchun LI, Fuyang CAO, Jun SHEN, Jianfei SUN and Chengsong CUI 33
Trying to remember the early days of casting simulation in JapanNIYAMA Eisuke, UCHIDA Toshio and ANZAI Koichi 45
Multiphase Flow Simulation in Mold Filling Process with Level Set Method
JingHAO, Liliang Chen, Dunming Liao and Jianxin Zhou 51
Heat and Mass Flow Modeling for Casting and Solidification Processes
Amethod of inverse evaluation for interface heat transfer coefficient between
aluminium alloys and cooling water
Zhonglin HOU, Shan YAO,Jianan YE
, Guiyong WU and Junze JIN 65
Modelling of the solidification of immiscible alloysHaili Li and Jiuzhou Zhao 73
Study of accretion formation near gas bottom-blowing tuyere in steel making process
by using a low temperature wax model
Chiung Chieh Kuo, Yu Pin Huang, Weng Sing Hwang, Chien Chih Yen and Tian IWu 81
Modification and verification of accretion similarity conversion method for
pyrometallurgical gas bottom-blowing process
Yu Pin Huang, Kuo Chiung Chieh, Weng Sing Hwang, Jia Shyan Shiau and SMh Hsien Liu 89
V
Numerical simulation for low pressure die casting ofAl-alloy motor enclosure and
technology improvementGuofa Ml, Xiangyu LIU, Kuangfei WANG and Lei LI 97
Modeling of direct chill casting of superlight Mg-Li alloysShuyan Shi, Hai Hao, Xingguo Zhang, Peng Guo and Junze Jin 105
Analyses of the influencing factors of rotating impeller degassing process and water
simulation experimentGuofa Mi, Xiangyu Liu, Kuangfei Wang, Shouping Qi and Hongwei Wang 113
Fluid Flow Modeling for Casting and Solidification Processes
Numerical simulation of filling process in casting with lattice Boltzmann method
Jianglin Huang, Liliang Chen, Dimming Liao and Jianxin Zhou 123
Mold filling simulation by finite difference method with high order scheme in regularcartesian gridTomoki Sawada and Koichi Anzai 131
Direct simulation of fluid flow and shrinkage using particle methodHirata NAOYA and Anzai KOICHI 139
Mold filling simulation of semi-solid AZ9 ID Magnesium AlloyRuey-Jer Weng, Jer-Haur Kuo,Weng-Sing Hwang,Chee-Ang Loong and Cheng-Kuei Jen 145
New algorithm of molten metal flow and heat transfer during casting processesXun SUN, Yang GUAN, Hailan LI, Shiyan ZHANG, Junqing WANG and Bo YU 153
Simulation of mold filling and solidification on gravity casting ofAl-Si alloy (A357)
Guofa M, Hengtao ZHAO, Kuangfei WANG and Zhi-anXU 159
Flow field and temperature filed simulation of directional solidification of
polycrystalline silicon ingotsShuyan Shi, Hai Hao
, Xingguo Zhang, Shan Yao, Yuanyuan Li and Junze JIN 167
The comparison of filling process between the LFC and simple cavity foundry bynumerial simulation
Jianan YE, Shan YAO, Guiyong WU, Xiaolin ZHAO and Junze JIN 175
Numerical simulation of filling process of crankshaft made from nodular cast ironXiaolin ZHAO, Shan YAO, Jianan YE, Guiyong WU and Junze JIN 179
Multi objective optimization of plunger speed using criterion for cold shut in die castingSAKURAGI Takuya and NAKAYAMA Ichiyou 185
The study of the modification of iteration convergence criterion for mold fillingRi Li, YingcuiJu, Cuigu Wu, Hanlong Liu andXingchuan Xia ..193
Numerical modeling of electron beam melting and casting of Ti-6A1-4V alloy ingotJindong Zhu, Daan Maijer, Steven Cockcroft, Xuanhe Zhao, David Tripp and Stephen Fox 201
VI
Study of micro-droplet behavior for a piezoelectric inkjet printing device usinga double pulse voltage pattern
Hsuanchung Wu, Jhenghong Chen, Wengsing Hwang and Hueyjiuan Lin 211
Crystal Growth and Microstructure Modeling
Modeling of dendritic structure and microsegregation in solidification of Al-rich
quaternary alloysTing Dai, Mingfang Zhu, Shuanglin Chen, Weisheng Cao and Chun-Pyo Hong 223
Cellular automaton modeling of solidification microstructure ofAl-Si alloyHongwei ZHANG, Keiji NAKAJIMA, Qiang WANG, Tie LIU, Wei XING and Jicheng HE 233
Phase field simulation of polycrystalline solidification in binary alloys
Junjie Li, Jincheng Wang and Gencang Yang 241
Cellular automaton - lattice Boltzmann model for the simulation of dendritic growthwith melt convection
Dongke Sun, Mingfang Zhu,Dierk Raabe and Chun-Pyo Hong 249
Phase-field simulation of lamellar growths for a binary eutectic alloy
Xinzhong Li, Jingjie Guo, Yanqing Su, Shiping Wu andHengzhi Fu 259
A CA-FD model for directional solidification ofAl-7%Si alloy with DC current
Xiaohui FENG, Yuansheng YANG and Wenhui TONG 267
Phase selection ofAISI304 stainless steel during directional solidification
Junwei FU, Yuansheng YANG, Jianchao MA.Wenhui TONG and Jingjie GUO 275
Influence of crystal orientation on growth velocity of polycrystalline silicon for solar cells
Hirofumi Miyahara, Yusuke Nakamura, Ichihito Narita and Keisaku Ogi 281
3D multi-phase field simulation on binary eutectic isothermal solidification
Yujuan Yang, Jincheng Wang, Yuxiang Zhang, Yaochan Zhu and Gencang Yang 289
Numerical simulation of solidification structure formation of casting in multi-component
alloy using PF-CA method
Kenichi Ohsasa, Yukinobu Natsume and Kiyotaka Matsuura 295
A 2-dimension cellular automaton modelling ofGTAW solidification microstructure
Xiaohu Deng, Liwen Zhang, Jibin Pei and Delun Guo 303
Microstructure evolution of the shell in centrifugal castingY.S. JANG, M.H. LEE
,J.Y. MOON and CP. HONG
,.311
Simulation Method and Calculation Algorithm
Integrated database construction for casting processes
In-Sung Cho, Seung-Mok Yoo, Chae-Ho Lim and Jeong-Kil' Choi.^..u.....-v., 321
Calculation time reduction of solidification analysis by implicit-explicit FDM
VII
ONDA HiroshUOlKAWA Katsunari and ANZAI Koichi 329
Application of advanced smooth technology to post-processing of finite difference data
Shengyong PANG, Liliang CHEN, Ruixiang LIU, Jianxin ZHOU and Dimming LIAO 337
Uneven FDM mesh technology and its application on casting's mold filling simulation
Jianxin ZHOU, Liliang CHEN, Dunming LIAO and Ruixiang LIU 345
Development of integrated simulation portal for casting processes on the net
Sang-Hyun CHO, Jeong-Tae KIMand Jeong-Kil CHOI 353
The construction of the casting expert system based on the database by utilizingsimulation and modeler
C.H. Lim, IS. Cho, S.M. Yoo and J.K. Choi 361
Study on cut-cell method for casting process simulation
Young-Sim CHOI, Jun-Ho HONG, Ho-Young HWANG and Jeong-Kil CHOI 371
Micro- and Macro-segregation
Using a multiphase approach to study the mechanisms which cause macrosegregationsMenghuai Wit, Laszlo Konozsy, Autumn Fjeld and Andreas Ludwig 379
Analysis of macrosegregation formation under the application of various types of
magnetic fields
X.D. Wang, A. Ciobanas, Y. Fautrelle, G. Zimmermann and A. Weiss 389
Effect of parameters on microsegregation patterns of Ni-Cu binary alloyChangsheng ZHU, Li FENG, Zhiping WANG andRongzhen XIAO 397
Stress and Deformation Modeling
Estimation and reduction of deformation defects in steel castings by a CAE system
Shinya Kanou, Kenji Ogawa, Akihiro Sato, Itsuo Ohnaka, Akira Sugiyama and Fumiaki Kinoshita 407
Simulation of thermal stresses and hot crack in the heavy ingot mould duringsolidification process
Lugui Chen, Ping Ma, Xiuhong Kang, Lijun Xia, Dianzhong Li and Yiyi Li 413
Research on the thermal simulation compression of spheroidal cast iron
Kai Qi, Zhixin Wang, Fudong Bai, Tingju Li and Meiqing Sun 423
Three-dimensional FEM numerical simulation of the die spinningZhi Yang, Wenlong Zhou, Liming Liu and YiXu 429
Continuous Casting/Direct Chill Casting
Simulation of continuous casting slab in induction heating processHao LIU, Liliang Chen, Jianxin Zhou and Dunming Liao 439
Crystallization of mold flux for continuous easting of steel by heat treatment
vni
Hidenori Mizuno, Hisao Esaka, Kei Shinozuka and Manabu Tamura 447
Mathematical modeling of the horizontal DC casting process for T-ingot productionM. Lane, M. DiCiano, DM. Maijer, S.L. Cockcroft and A. Larouche 455
Modeling wire rod of continuous castingHungju Chang, Weihien Jang, Dechang Tsai, Weng-sing Hwang, Longsun Chao and Yangming Lit 465
Coupled numerical simulation of flow field and temperature field for inner-outer coupled
cooling slab continuous castingXiaochao CUI, Yanjuan JIN, Zhu ZHANG andJunting ZHANG 473
Numerical simulation of mold filling and solidification process for beam blank
continuous casting
Yanjuan JIN, Xiaochao CUI, Puyu ZHANG and Zhu ZHANG 481
Investigation on mould heat transfer in continuous casting of round billet
Liangliang Guo,Man Yao, Xudong Wang and Hebi Yin 489
Mathematical and PIV physical simulation for melt flow in continuous casting of
aluminum alloy slab
Xu Xuan, Xingguo Zhang, Huanyue Zhang, Canfeng Fang and Hai Hao 499
Electromagnetic Coupling
Effect of multi-electromagnetic fields on the quality of continuous casting hollow billet
Qi ZHANG, Tongmin WANG, Tingju LI andJunze JIN 509
Numerical simulation of thermal and flow fields in induction skull melting process
GuanxiaXUE, Tongmin WANG, Yanqing SU, Too SONG, Qi ZHANG,Jingjie GUO, Tingju LI and
Junze JIN 517
Research of computing method of the magnetic field distribution in the soft-contact mold
Xianshu ZHENG, Fangyi QU, Yongdong ZHOU and Junze JIN 525
Computer simulation of electromagnetic field and shape of liquid column in round ingotelectromagnetic castingFeng Qi, Tingju Li, Junze Jin and Yihai Sun 533
Study on the form position of the air gap between mould and ingot in electromagneticcontinuous castingFeng Qi , Tingju Li and Junze Jin 541
Temperature simulation of electromagnetic continuous casting ofAZ61 magnesium billets
Yue Qiu, Xingguo Zhang, Hai Hao, Peng Guo and Canfeng Fang 545
Effect on the movement behavior of non-metallic particles under electromagnetic field
Zhongtao Zhang, Qingtao Quo,Jim ZHANG and Tingju LI,
553
Two-phase flow simulation on hollow billet solidification under rotating and traveling
magnetic fields
IX
Tongmin Wang, Qi Zhang, Tingju Li and Junze Jin 559
Casting Defects and Their Prediction
Hot tearing of aluminum alloys: influence of intermetallic compounds crystallizationat later stage of solidification
NAGAUM Hiromi and UMEDA Takateru 569
Modeling of centerline defects and it's application on soft reduction of continuous casting
Tingli WANG, Shan YAO,Hai HAO, Zhonglin HOU and Junze JIN 577
Prediction and reduction of inclusion defects in steel castings by a CAE system
Shinya Kanou, Kenji Ogawa, Itsuo Ohnaka, Akira Sugiyama and Fumiaki Kinoshita...585
Numerical simulation methods to predict the gas porosity defects
Jun-Ho HONG, Young-Sim CHOI, Ho-Young HWANG andJeong-Kil CHOI 591
Advanced Solidification and Materials Processing
In-situ observation of solidification of Sn-Ag alloysHisao Esaka, Mizuho Sakuta, Kei Shinozuka and Manabu Tamura 601
Control of solidified structures and intergranular precipitations in Al-Li binary alloys byhigh magnetic fields
Tie Liu, Qiang Wang, Ke Wang, Yi Yuan, Hongwei Zhang,Keiji Nakajima andJicheng He 607
An efficient tabulation technique for multi-scale solidification modeling of
multi-component alloysQ. Du, D.G. Eskin and L.Katgerman 613
Effects of diameters and chiralities on the optical properties of single-walled carbon
nanotubes by first principlesYu Zhang, Bin Wen, Jijun Zhao, Mingshan Zhao, Xingguo Zhang and Tingju Li 621
Manufacturing of silicon ingot by metallurgic castingJian ZHANG, Xiaodong MA, Zhongtao ZHANG and Tingju LI 629
Assessing controllability of low pressure die casting using process simulation
Xinmei SHI, Daan M. MAIJER and Guy DUMONT 635
Numerical study on rheocasting A356 alloy using cooling slope methodXiaoli Zhang, Tongmin Wang, Tingju Li, Haitao Teng.Bin Wen, Shuisheng Xie and
Junze Jin 643
Pattern-less rapid casting and rapid process evaluation
Changke YE, Shan YAO, Jianan YE, Guiyong WU and Junze JIN 649
Development of new semi-solid method and practical application to bearing bracketsJ.G. Sim, J.Y. Moon, J.M. Kim and CP. Hong 657
X
Industrial Applications of Modeling and Simulation
Computer modelling of deformation and annealing processes and their industrial
applicationsHualongLi, PARK Jong-Tae, PARK Sooho and SZPUNAR Jerzy 665
Experience of industrial application of commercial software for casting processes
simulation
V.P. Monastyrskiy and I.L.Koynov 671
Numerical simulation and technology optimization for producing large-sized castingsJunqing WANG, Xun SUN, Yang GUAN, Penghua WANG, Hailan LI, Bo YU, Limei BAI and
Xinzhi SUN 679
Prediction of room temperature mechanical properties in aluminium castingsZhanli GUO, Nigel SAUNDERS, Peter MODOWNIK and Jean-Philippe SCHILLE 687
Application of mathematical models to development of new open mould conveyor
ingot casting technologyJ. Grandfield, T. Nguyen, P. Rohan, V. Nguyen, M. Prakash and P. Cleary ..701
XI