A finite element model for the simulation of lost foam casting

In this paper, we present a numerical model to simulate the lost foam casting process. We introduce this particular casting first in order to capture the different physical processes in play during a casting. We briefly comment on the possible physical and numerical models used to envisage the numerical simulation. Next we present a model which aims to solve ‘part of’ the complexities of the casting, together with a simple energy budget that enables us to obtain an equation for the velocity of the metal front advance. Once the physical model is established we develop a finite element method to solve the governing equations. The numerical and physical methodologies are then validated through the solution of a two‐ and a three‐dimensional example. Finally, we discuss briefly some possible improvements of the numerical model in order to capture more physical phenomena. Copyright © 2004 John Wiley & Sons, Ltd.