Thermal analysis of piston casting using 3-D finite element method

This paper presents a finite element modelling of metal solidification, applied to an aluminum-silicon alloy piston casting. Earlier studies on solidification have been mostly confined to one- and two-dimensional problems whereas the present one deals with 3-D castings. It is assumed that the heat transfer within the melt is by conduction and that from the melt/casting to the mold is by the interfacial heat transfer process. The air gap formed between the casting and the mold at interface affects the heat transfer rate. A finite element formulation for the heat transfer through the air gap is presented for the 3-D problems. The same is applied to the specific case of piston solidification. Temperature profiles at different time steps are presented. The time taken for completion of solidification with respect to the process parameters are discussed. (C) 2001 Elsevier Science B.V. All rights reserved.