Course Syllabus for students Autumn 2024

After a successful course, the student shall:

• show familiarity with use of casting simulation in the development of new casting processes
• display knowledge of analytical and numerical methods used to calculate phenomena associated with casting.
• demonstrate comprehension of how material properties and boundary conditions affect the calculation results.

• demonstrate skills of using analytical formulas and numerical programing of heat transport and solidification phenomena in relation to casting of metallic materials.
• demonstrate the ability to use professional software to optimize mold filling and resulting cast material properties.

• demonstrate the ability to chose adequate calculation methods and models for various kinds of cast materials.
• demonstrate an understanding of validation methods to determine if calculation results reflect real phenomena associated with casting.

The course covers trends in programing and simulation of solidification phenomena of cast metals. Examples from applications for process and materials development, solutions of technological problems using casting simulation. An analytical part treats the basic heat transport and solidification. A numerical part treats the heat equation by conduction using the Finite Different Method (FDM). Numerical solution of solidification via the Enthalpy method and associated heat transport is solved with the control volume based finite difference method FDM-CV. Numerical solutions based on 1D formulation are solved in MATLAB and compared with simulation in a commercial 3D simulation software.

The course includes:
• Fundamentals of heat flow and solidification
• Programming the heat flow and solidification
• Use of professional casting simulation software
• Validation of the casting simulation

Teaching consists of lectures mixed with calculation exercises, laboratory work with programming 1D program codes to calculate heat conduction and solidification, laboratory work with commercial 3D program to test optimization of casting and solidification of cast components.

The teaching is conducted in English.

Passed courses at least 90 credits within the major subject Mechanical Engineering, 15 credits Mathematics, and completed course in Component Casting, 6 credits, and Solidification Processing, 3 credits, and proof of English proficiency is required (or the equivalent).

The course is graded 5,4,3 or Fail.

The final grade for the course is based on a balanced set of assessments. The final grade will only be issued after satisfactory completion of all assessments.

Name of the Test	Value	Grading
Examination	3 credits	5/4/3/U
Submission task	3 credits	5/4/3/U

Exemption from entry requirement allowed according to the selection groups of the program, where the course is included.

The literature list for the course will be provided eight weeks before the course starts.
Compendium based on "Fundamentals of Numerical Modelling of Casting Processes" by Jesper Hattel. Formula and exercise collection from Attila Diószegi. User's manual for program codes: MATLAB, Magma Soft, NovaFlow & Solid, Flow 3D, ProCast or Fluent.