Numerical modeling of heat transfer through casting–mould with 3D/1D patched transient heat transfer model

Abstract This paper focuses on the development of a 3D/1D patched transient heat transfer model (called 3D/1D patched model). It is proposed for getting accurate thermal boundary conditions in investment castings. In the 3D/1D model, heat transfer in the mould is assumed to take place only in a direction perpendicular to the mould, called 1D heat transfer and is computed via the FD solution of a 1D heat transfer equation. To reduce computational cost and simplify the mesh generation, the coordinates of cell centre and the temperature in the mould can be calculated by the model instead of meshing mould. When 1D patched model is integrated into the 3D CFD code PHYSICA, An area is present where 3D/1D model cannot cover, called ‘dead corner’. To overcome the effect of ‘dead corner’, a patch is introduced to put on it. The simulation results show that the 3D/1D patched model improves the accuracy when calculating the heat transfer through the mould–casting interface. However, it does not function well in 3D geometrical model.