In the REALTIME Advanced Grant project we have developed new and extremely fast algorithms for parallel computing analysis of flows involving several fluids with different properties (the so-called multi-fluids). These computational techniques are applicable to gas-liquid transport, crude oil recovery, spray cans, fuel injection in engines and many other industrial processes.
In the FORECAST Proof of Concept (PoC) we have explored the industrial applicability and potential for commercialization of the new fast simulation technology developed in REALTIME for the enhanced design of mould filling processes in casting manufacturing operations of mechanical components.
Fast simulation in the context of the FORECAST PoC means computer analyses carried out typically one or two orders of magnitude faster than current commercial codes using multi-processor computers available to the SMEs in the casting sector.
The computational technology developed in FORECAST will allow the casting industry, and in particular SMEs, to solve mould filling problems in times useful for taking decisions helping the design and operation of casting processes. In addition to this relevant aspect, the FORECAST PoC technology will allow users taking into account the multi-fluid character of mould filling processes, including coupled thermal-flow effects in both the air contained in the mould and the molten metal, and heat transfer between the flowing melt and the mould walls. Up to date a commercial casting simulation code including such comprehensive features of computational speed and advanced physics is simply not available.
The FORECAST PoC will, in summary, greatly help move the REALTIME software technology towards the initial steps of an innovation process leading to a new extremely fast and accurate mould filling simulation software for enhanced design of casting manufacturing operations of mechanical components for a wide range of applications in industry.
