In this study an algorithm for MOLD-FILLING simulation with consideration of surface tension has been developed based on a SOLA VOF scheme. As the governing equations, the Navier-Stokes equations for incompressible and laminar flows were used. We proposed a way of considering surface tension in MOLD-FILLING simulation. The proposed scheme for surface tension was based on the continuum surface force (CSF) model; we could confirm the remarkable effectiveness of the surface tension by experiment which concluded in very positive outcome.

The MOLD-FILLING behavior in the casting of aluminum alloy (A413) using lost foam casting (LFC) was explored. The effects of gate numbers, type of gating and casting thickness on the FILLING behavior were evaluated. Although, unlike convectional casting process, the gating system showed little effect onFILLING ability, casting thickness created a greater effect on the MOLD FILLING. In contrast with convectional casting process, the MOLD FILLING seems to be controlled by castinggeometry as a consequence of combined influence of heat and mass transfer. The melt used to enter from the first gate instead of last gate which is in contrast with convectional casting process.

The present work reports and discusses the results of a 3D simulation of the injection MOLDing process of a rubber compound that includes the MOLD FILLING stage and material curing, using the computer code is developed in "UDF" part of the Fluent 6.3 CAE software. The data obtained from a rheometer (MDR 2000) is used to characterize the rubber material in order to find the cure model parameters which exist in curing model. Because of non-newtonian behavior of rubber, in this work the non-newtonian model for viscosity was used and viscosity parameters were computed by mean of viscometry test by RPA. After calculation of the physical and curing properties, vulcanization process was simulated for a complex rubber article with non-uniform thickness by solving the continuity, momentum, energy and curing process equations. Predicted FILLING and curing time in a complex and 3D rubber part is compared with experimentally measured data which confirmed the accuracy and applicability of the method.

In this investigation, α 2-D Finite Volume Method (FVM) with unstructured triangular mesh is developed to simulate the mould FILLING process. The simulation of fluid flow and track of free surface is based on the Marker And Cell (MAC) technique. This technique has capability of handling the arbitrary curved solid boundaries in the casting processes. In order to verify the computational results of the simulation, a thin disk plate with transparent mould was tested. The mould FILLING process was recorded using a 16mm high-speed camera. Images were analyzed frame by frame, in order to tracking of free surface and FILLING rate during mould FILLING. Comparison between the experimental method and the simulation results has shown a good agreement.

In the present study a Finite Difference Method has been developed to model the transient incompressible turbulent free surface fluid flow. A single fluid has been selected for modeling of MOLD FILLING and The SOLA VOF 3D technique was modified to increase the accuracy of simulation of FILLING phenomena for shape castings. For modeling the turbulence phenomena k-e standard model was used. In order to achieve an accurate model, solving domain was discrete to three regions includes: laminar sub layer, boundary layer and internal region. This model was applied to experimental models such as a driven cavity, Campbell benchmark [1] and top filled cavity. The results show that the suggested model yield favorable predictions of turbulence flow and have a good consistency in comparing with experimental results.

Resin Transfer MOLDing (RTM) is a composite manufacturing process. A preformed fiber is placed in a closed MOLD and a viscous resin is injected into the MOLD. In this paper, a model is developed to predict the flow pattern, extent of reaction and temperature change during FILLING and curing in a thin rectangular MOLD. A numerical simulation is presented to predict the free surface and its interactions with heat transfer and cure for flow of a shear-thinning resin through the preformed fiber. Finite difference method with marker and cell procedure has been used for front flow position prediction. To verify the model results, the temperature profiles for preformed fiber have been calculated, and compared with the experimental results of the other researchers. The results showed that, to optimize the better quality of production of composite materials, and also considering the effect of curing on temperature distribution during the process, the heat dispersion term should not be neglected.

In the present study a finite difference method has been developed to model transient fluid flow and heat transfer in metal casting. A single fluid has been selected for modeling the MOLD FILLING and the SOLA VOF 3D technique was modified to increase the accuracy and speed of simulation of FILLING phenomena for shape castings. The model was then evaluated with the experimental methods. Referring to the experimental and simulation results, a good consistency and accuracy of the suggested model are observed.

New forming processes should be capable of manufacturing complex and high quality components in addition to low production costs and high production speeds. The gas pressure forming process is one of the methods used in forming these parts. In this research, the formation of Al-A356 alloy sheet in incomplete cone with gas pressure process has been studied numerically and experimentally. In general, it can be said that the purpose of this study is to investigate the effect of parameters such as the ratio of diameter to height of the die, angle, temperature and pressure. In order to determine the effect of parameters, FILLING the corners of the die and distributing the thickness of the parts under different pressures has been investigated. Also, for simulating validation, the simulation results were first compared with experimental tests. The results show that the MOLD FILLING will improve around 15% by increasing the pressure from 1 bar to 8 bar. However, is reduced to less than 0. 5 mm. Although, the MOLD FILLING increased by decreasing of the ratio of diameter to height but the critical thickness of the sheet is decreased around 14%. It was also found that for having a proper MOLD FILLING, it is necessary to increase the pressure value around 25% when the cone angle decrease from 30º,to 0º, . The results also showed that by increasing the temperature from 350°, C to 550°, C, the required pressure for FILLING the MOLD decreased from 8 to 2 bar.