PHASE-CHANGE ANALYSIS OF ALUMINIUM FLYWHEEL CASTING USING THERMAL ANALYSIS

Abstract

Solidification behavior significantly influences the structural integrity and defect formation in cast
components. This study presents a transient finite element simulation of the solidification of an
aluminum flywheel casting within a sand mold using ANSYS Mechanical (Transient Thermal).
A two-dimensional axisymmetric model is employed to represent the rotational symmetry of the
flywheel geometry, reducing computational effort while preserving physical accuracy. The
enthalpy-based formulation is used to incorporate latent heat effects within a narrow mushy zone
(695–697 °C). Temperature evolution, solidification time, and spatial progression of the solid–
liquid interface are analyzed.