High-Performance Simulation of Mold Filling Using Porous Media Method

The need to speed up calculation and improve analytical accuracy of Casting CAE has grown with optimized casting planning and speeded-up product design. A finite difference method using regular grid of Cartesian coordinates is often used in simulating mold filling because it reduces memory requirements, computation time and easier grid generation. Its disadvantage is that shape expression becomes less precise so that casting slopes and curved surfaces are replaced to stair-step shape. The mold filling simulation developed using porous media method in this paper provides uses two control volume parameters -- porosity rate of grid volume and permeability of grid surface -- to maintain shape expression and analytical accuracy. Results used larger grids than conventionally have with almost the same accuracy as analysis with fine grids. It has also advantages saving on memory and computation time.