Thermo-mechanical analysis of cast/mould interaction in casting processes

The numerical analysis of the thermo-mechanical interaction between the cast part and mould in casting processes requires a strong coupling between the thermal and mechanical simulation. This includes a 3-D frictionless contact algorithm and a model to describe the local heat transfer between part and mould as a function of the contact pressure or the formation of a local gap between both domains. Several features suitable for the analysis of solidification processes have been introduced in the classical master/slave contact algorithm like a temperature-dependent penalty factor and implemented in the software package CASTS. Benchmark tests and two industrial casting applications illustrate the correctness of the developed thermo-mechanical program and the ability to simulate complex cast parts.