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This study presents a highly detailed framework for implementing digital twin technology for the aluminumAluminum direct chill (DC) castingCasting process. The framework focuses on the meltingMelting and filtration stages, which have historically posed significant challenges for traditional simulationSimulation methods due to their complex, multiscale, and multiphysics characteristics. The study employs advanced numerical simulationNumerical simulation techniques, such as computational fluid dynamics (CFDComputational Fluid Dynamics (CFD)), the discrete element method (DEM), and conjugate heat transferHeat transfer (CHT) modelingModeling, to accurately replicate real-world castingCasting operations in a virtual environment. These simulationsSimulation were constructed using industrial-scale operational data and experimentally validated thermophysical propertiesProperties with open-source (OpenFOAM) and commercial (Ansys Rocky™—all trademarks are abbreviated below—and Ansys Fluent) software. The resulting digital framework facilitates visualization and prediction of internal process dynamics, as well as facilitating virtual experimentation, performance diagnostics, and process optimizationOptimization under varying operational conditions. This paper details the methodology and implementation of the proposed simulationSimulation architecture and validates its accuracyAccuracy through comparison with experimental measurementsMeasurements.

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Establishment of Digital Twin Technology on Aluminum Melting and Filtration

  • 会议论文

  • 发表日期：

    2026年

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  • Keisuke Kamiya,
  • Fumiya Nozaki,
  • Akira Suzuki,
  • Chihiro Matsuno

摘要

This study presents a highly detailed framework for implementing digital twin technology for the aluminumAluminum direct chill (DC) castingCasting process. The framework focuses on the meltingMelting and filtration stages, which have historically posed significant challenges for traditional simulationSimulation methods due to their complex, multiscale, and multiphysics characteristics. The study employs advanced numerical simulationNumerical simulation techniques, such as computational fluid dynamics (CFDComputational Fluid Dynamics (CFD)), the discrete element method (DEM), and conjugate heat transferHeat transfer (CHT) modelingModeling, to accurately replicate real-world castingCasting operations in a virtual environment. These simulationsSimulation were constructed using industrial-scale operational data and experimentally validated thermophysical propertiesProperties with open-source (OpenFOAM) and commercial (Ansys Rocky™—all trademarks are abbreviated below—and Ansys Fluent) software. The resulting digital framework facilitates visualization and prediction of internal process dynamics, as well as facilitating virtual experimentation, performance diagnostics, and process optimizationOptimization under varying operational conditions. This paper details the methodology and implementation of the proposed simulationSimulation architecture and validates its accuracyAccuracy through comparison with experimental measurementsMeasurements.