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Tutorial # 3 ANSYS (Thermal) By: Nicolás Hernández Jiménez FEM 2020-04-06

This document summarizes a tutorial on simulating the solidification of a steel casting using ANSYS. It describes the L-shaped steel casting and sand mold, including material properties and initial conditions. The model simulates heat transfer by conduction, convection and phase change during solidification over time. The simulation shows temperature distributions, heat transfer mechanisms, and the solidification process from molten to solid steel over approximately 2 hours.

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Nicolás Hernández Jiménez
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44 views6 pages

Tutorial # 3 ANSYS (Thermal) By: Nicolás Hernández Jiménez FEM 2020-04-06

This document summarizes a tutorial on simulating the solidification of a steel casting using ANSYS. It describes the L-shaped steel casting and sand mold, including material properties and initial conditions. The model simulates heat transfer by conduction, convection and phase change during solidification over time. The simulation shows temperature distributions, heat transfer mechanisms, and the solidification process from molten to solid steel over approximately 2 hours.

Uploaded by

Nicolás Hernández Jiménez
Copyright
© © All Rights Reserved
We take content rights seriously. If you suspect this is your content, claim it here.
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Tutorial # 3 ANSYS (Thermal)

By: Nicolás Hernández Jiménez


FEM 2020-04-06
Solidification of a Casting

After the Structural Tutorial it is now intended to understand the thermal properties within
the solidification of a casting, where the conduction , convection ,phase change , selecting ,
solution control and time- history-postprocessing are settled. The environment of
development will be ANSYS APD.
First , it is shown the cast as a steel piece in figure 1. A L-shaped sand mold with four-
inch-thick walls is required to allow the convection occurs between the sand mold and the
outside.

Figure 1. L-shaped steel piece to be casted.

The main objective is to express the temperature distribution during the solidification.
Some Data as some assumptions are the following:

Material Properties for Sand:

- Conductivity : 0.025 Btu /( hr-in-°F)

- Density : 0.054 lb/in3

- Specific Heat: 0.28 Btu/( lb- °F)


Material Properties for Steel

- Conductivity: 0°F (1.44 Btu/hr-in-°F) , 2643°F ( 1.54), 2750°F ( 1.22), 2875°F ( 1.22)
- Enthalpy: : 0°F (0.00 Btu/in3) , 2643°F ( 128.1), 2750°F ( 163.8), 2875°F ( 174.2)

Initial Conditions:

- Temperature of Steel : 2875 °F


- Temperature of Sand : 80°F
Convection Properties

- Film Coefficient: 0.014 Btu/(hr-in^2-°F)


- Ambient Temperature : 80°F

According to symmetry, the model will be treated as the lower part , as Figure 2
shows.

Figure 2. Mold and Steel Symmetry aspects.

After setting the data in the program preprocessing the following images
are shown:

Figure 3. Temperature vs Enthalpy.

.
Figure 4. Temperature vs Conductivity ( KXX)

Figure 5. Two Material Meshing

With the Geometry selected , the meshing is generated as Figure 5


shows and then the convection loads on the boundary lines are applied.
Figure 6. Convections Loads applied

SOLUTION
Right after applying the convection loads , the solution is created.

Figure 7. Graphical Solution Tracking.

In Figure 7 the Graphical Solution Tracking is shown , plotting the


Absolute Convergence Norm as a function of the Cumulative Iteration
Number. Likewise , the solution chart appears as the plot of temperature
vs time on the post- processing.
Figure 8 . Solution Chart .

Figure 9 . Temperature vs Time.

Finally, the animation through Plot Controls is made and shown in the
following sequence.
Figure 10 , 11 Time 0 and 0.2 of Solidification

Figure 12 , 13 Time 0.42 and 0.56 of Solidification

Figure 14 , 15 Time 1.1 and 1.52 of Solidification

 From Figure 9 is noticeable the solidification region approximately between 2643°F


and 2750 °F.
 In order to fulfill with the animation , a setup with materials and colors is required.
 Around 1 hour and 52 minutes after the beginning of the solidification, the casting
achieved an entirely solid state.
 The duration of the molten metal within the casting lasted approximately 58 minutes.
 Intermediate green phase appeared surrounding all the corners about 20 minutes after
Pouring.
 2 hours are necessary enough to extract the casting and not 4 hours as initially
thought.

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