Experimental characterisations and numerical simulation of fluid-structure interactions for casting control
Résumé
Hollow turbojet blades are manufactured by a lost-wax casting process. After several steps aimed at manufacturing a consumable mold with inserts, the pouring or casting phase is a key step in the process, which consists of pouring a nickel-based superalloy at liquid state into the mold and then solidifying it. In order to improve the manufacturing process, chiefly the pouring step, the interaction between the molten metal and the thin walls of the casting mold are studied for several flow rates representative of the process. In order to better understand this interaction, which is difficult to observe during a casting, we use a test-calculation dialogue. Hydrodynamic and fluid-structure interaction calculations are correlated and validated using an experimental setup developed specifically for this study, in which molten metal is replaced by water based on Reynolds number similarity. A model of the experimental test bench was carried out with thecalculation code FLOW-3D®, a CFD tool dedicated to free surface movements including a fluid-structure model. The results of the flow calculations allow to find the trends of the velocity field in the fluid around the structure and its displacement with a good agreement with the experimental observations.
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