3D Casting simulation

THERCAST is a powerfull 3D simulation tool for the optimization of casting and foundry processes as well the classical filling and cooling processes as the continuous casting processes.

Model ingredient

Thermo-mechanical model

THERCAST is a casting software which objective is to simulate the filling and the cooling of foundry parts in metal or sand molds. In order to simulate the liquid well, Navier-Stokes behavior with thermal dependant terms is used, the mushy zone has got a thermo-viscoplastic behavior and the solid one, a thermo-elastic-viscoplastic behavior.

A coupled computation leads to a deformation of the molds which can be non-rigid. In that case, they have a thermo-elastic-viscoplastic and/or thermo-elastic-plastic behavior.

THERCAST gives access to temperature distribution in part and molds and true casting deformations such as air gap between part and molds and open shrinkage in the part. In addition, residual stresses and strain are computed in part and molds.

THERCAST is based on a non-stationary 3D finite element method. The discretization of part and mold components is performed using an enhanced (P1+/P1) 4-node tetrahedron elements. The use of non coincident volume tetrahedron meshes of casting domains is an unique characteristics of THERCAST.

In addition, the ALE method and Navier-Stokes behavior in the liquid well are used to complete the possibilities of THERCAST  in simulating the natural convection. An automatic remeshing procedure enables the simulation of geometrically complex parts such free surface movement and open shrinkage.

The specificity of THERCAST  takes place in the fact that a mixed behavior is used to simulate the cooling of the part from liquid phase to solid phase. The behavior from hot to warm state is a Norton-Hoff type behavior (Navier-Stokes for pure liquid phase) and the behavior for the cold state is a elastic-viscoplastic completed with a Perzina term.

Both are completed with a specific term for thermal linear volume change. The behavior of the metal molds is elastic-viscoplastic. The behavior of the sand molds is elastic-plastic.