Finite element modeling of the lost foam casting process tackling back‐pressure effects

Abstract

Purpose To develop a numerical methodology to simulate the lost foam casting (LFC), including the gas back‐pressure effects.

Design/methodology/approach Back‐pressure effects are due to the interactions of many physical processes. The strategy proposed herein tries to model all these processes within a simple formula. The main characteristic of the model consists of assuming that the back‐pressure is a known function of the external parameters (coating, temperature, gravity, etc.) that affects directly the heat transfer coefficient from the metal to the foam. The general framework of the simulation is a finite element model based on an arbitrary Lagrangian Eulerian (ALE) approach and the use of level set function to capture the metal front advance.

Findings After experimental tunings, the model provides a way to include the back‐pressure effects in a simple way.

Research limitations/implications The method is not completely predictive in the sense that a priori tuning is necessary to calibrate the model.

Practical implications Provides more realistic results than classical models.

Originality/value The paper proposes a theoretical framework of a finite element method for the simulation of LFC process. The method uses an ALE method on a fixed mesh and a level‐set function to capture metal front advance. It proposes an original formula for the heat transfer coefficient that enables one to include back‐pressure effects.