Mathematical Modelling (FSI-PMM)

Academic year 2022/2023
Supervisor: Ing. Vladimír Krutiš, Ph.D.  
Supervising institute: ÚST all courses guaranted by this institute
Teaching language: Czech
Aims of the course unit:
The aim of the course is to explain all the stages of simulation preparation and to give a compact view of the possibilities of computer assisted systems in the area of foundry processes.
Learning outcomes and competences:
Student will acquire the knowledge of 3D modelling of castings, definition of initial and boundary conditions of numerical simulation, evaluation of simulation results. The optimisation of gating and feeding systems is done using real castings and is performed for all foundry processes (gravity sand and die casting, high pressure die casting, investment casting, semi-solid processes). Calculation of production costs and sale price of castings together with Pacyna’s classification of castings is described. Relationships between other modules for thermo-mechanical calculation of castings are shown. The calculations are carried out with the support of modern software products.
Prerequisites:
Basic knowledge of Foundry technology, knowledge of liquid flows and heat transfer, basic computer skills
Course contents:
Due to the development of computer technology, the numerical simulation has become helpful in designing and optimising foundry processes. Mathematical simulation is aimed at the tuning of the designed technology in the phase of production preparation in order to avoid expensive experimental testing. The simulation of foundry processes connects numerical methods, physics and computer technology. It enables the study of processes during melt flow, solidification and cooling of castings.
Teaching methods and criteria:
The course is taught through lectures explaining the basic principles and theory of the discipline. Exercises are focused on practical topics presented in lectures.
Assesment methods and criteria linked to learning outcomes:
Course – unit credit requirements-optimisation of real casting technology, participation in the lessons
Exam - written and oral parts
Controlled participation in lessons:
Participation in seminars is required. An apologized absence from seminars may be compensated by individual work.
Type of course unit:
    Lecture  13 × 1 hrs. optionally                  
    Computer-assisted exercise  13 × 2 hrs. compulsory                  
Course curriculum:
    Lecture 1. Introduction to numerical simulation of foundry processes
2. Application of CAD system in foundry processes
3. Methods of numerical simulation
4. Basic knowledge of heat transfer
5. Initial condition definition
6. Boundary condition definition
7. Thermo-physical properties
8. Calculation of porosity defects in casting
9. Simulation of gravity sand casting technology
10. Simulation of high-pressure die casting technology
11. Investment casting technology
12. Special processes – semi-solid processes
13. Post-processing and industrial cases
    Computer-assisted exercise 1. Geometry design – data import and export
2. Preparation of surface and volume meshes
3. Repairing of bad meshes
4. Definition of initial and boundary conditions
5. Calculation definition – modules, calculation steps
6. Examples of gravity casting calculation
7. Examples of pressure casting calculation
8. Examples of investment casting calculation
9. Calculation of special processes
10. Porosity calculation
11. Optimisation of gating and feeding systems
12. Post-processing
13. Results validation
Literature - fundamental:
1. BONOLLO, F., ODORIZZI, S. Numerical Simulation of Foundry Processes. 1st ed. Padova: S.G.E., 2001, 264 p. ISBN 88-86281-63-3
2. Nová, I.:Tepelné procesy ve slévárenských formách, TU Liberec, 2003
3. Rappaz M., Dantzig A. : Solidification, 2nd edition. EPFL Press, 2016. ISBN 978-0-84938-238-3
Literature - recommended:
1. Herman, A. a kol.: Počítačové simulace ve slévárenství, Vydavatelství ČVUT, 2000
2. Hattel JH, Pryds N, Thorborg J, Lipinski M, Schneider M, Hattel JH, (ed.).: Fundamentals of Numerical Modelling of Casting Processes. Polyteknisk Forlag, 2005. 540 p.
3. Abhilash E., Joseph M. A.: Modelling and Simulation of Casting Process: an Overview, Indian Foundry Journal, Vol. 55, No.10, 2009, pp 28-37 https://www.researchgate.net/publication/270757498_Modelling_and_Simulation_of_Casting_Process_an_Overview)
The study programmes with the given course:
Programme Study form Branch Spec. Final classification   Course-unit credits     Obligation     Level     Year     Semester  
CŽV full-time study CZV Bases of Mechanical Engineering -- GCr 4 Compulsory 1 1 S
N-SLE-P full-time study --- no specialisation -- GCr 4 Compulsory 2 1 S