Transient Thermal Observation for Casting of Assembly of Aluminum Alloy with Sand Mold & Mullite Mold

Abstract

In this analysis simulation in two dimension for solidification of aluminum alloy with greensand AI50/60 (AFS) & with mullite mold by finite element method and ANSYS software has been donefor it thermophysical properties of sand and mullite taken dependent on temperature but aluminum alloy properties are constant along convection heat transfer taken in consideration on mold external surface due to dependency of properties of mold on temperature. For this the problem modelling have non-linear equation. Effect of heat transfer shown in two-dimension with thermal gradient, effect of thermal flux and convergence curves that control the feasibility of Newton-Rapson algorithm process.

 Due to complex physics concept in applied in whole process of casting there are various parameter to control the perfection of casting. Mold design also matter which to be optimize. A methodology developed on optimization technique of cavity wall & cavity-cavity gap for casting to find a proper layout and the number of cavity in a mold .We done observation on heat transfer process in the casting .Resistant within casting due to solidified metal , metal mold interface and the mold have major part in thermal resistant & the liquid & surrounding of the mold have vey low participation which can be neglect. Resistant due to air gap in between solidify metal & mold also having major impact on casting microstructure &quality of casting it is a great resistant for heat transfer . In this paper we understand phenomena involved solidification of casting , to find the several parameters which affect solidification of casting & interrelation between these parameter . a mathematical model also developed to get correct understanding of the heat dissipation in the casting finally applied the ANSYS to get correct understanding. The  effect of different-different mold on the heat distribution is main work done here to get a good casting for a specific purpose. Here temperature variation in the aluminum casting & mold during solidification process studied.