Three-dimensional free surface modelling in an unstructured mesh environment for metal processing applications

In the casting of metals, tundish flow, welding, converters, and other metal processing applications, the behaviour of the fluid surface is important. In aluminium alloys, for example, oxides formed on the surface may be drawn into the body of the melt where they act as faults in the solidified product affecting cast quality. For this reason, accurate description of wave behaviour, air entrapment, and other effects need to be modelled, in the presence of heat transfer and possibly phase change. The authors have developed a single-phase algorithm for modelling this problem. The Scalar Equation Algorithm (SEA) (see Refs. 1 and 2), enables the transport of the property discontinuity representing the free surface through a fixed grid. An extension of this method to unstructured mesh codes is presented here, together with validation. The new method employs a TVD flux limiter in conjunction with a ray-tracing algorithm, to ensure a sharp bound interface. Applications of the method are in the filling and emptying of mould cavities, with heat transfer and phase change.

Scalable unstructured mesh decomposition

As the efficiency of parallel software increases it is becoming common to measure near linear speedup for many applications. For a problem size N on P processors then with software running at O(N=P ) the performance restrictions due to file i/o systems and mesh decomposition running at O(N) become increasingly apparent especially for large P . For distributed memory parallel systems an additional limit to scalability results from the finite memory size available for i/o scatter/gather operations. Simple strategies developed to address the scalability of scatter/gather operations for unstructured mesh based applications have been extended to provide scalable mesh decomposition through the development of a parallel graph partitioning code, JOSTLE [8]. The focus of this work is directed towards the development of generic strategies that can be incorporated into the Computer Aided Parallelisation Tools (CAPTools) project.