Lattice Boltzmann model for free-surface flow and its application to filling process in casting

A generalized lattice Boltzmann model to simulate free-surface is constructed in both two and three dimensions. The proposed model satisfies the interfacial boundary conditions accurately. A distinctive feature of the model is that the collision processes is carried out only on the points occupied partially or fully by the fluid. To maintain a sharp interfacial front, the method includes an anti-diffusion algorithm. The unknown distribution functions at the interfacial region are constructed according to the first-order Chapman–Enskog analysis. The interfacial boundary conditions are satisfied exactly by the coefficients in the Chapman–Enskog expansion. The distribution functions are naturally expressed in the local interfacial coordinates. The macroscopic quantities at the interface are extracted from the least-square solutions of a locally linearized system obtained from the known distribution functions. The proposed method does not require any geometric front construction and is robust for any interfacial topology. Simulation results of realistic filling process are presented: rectangular cavity in two dimensions and Hammer box, Campbell box, Sheffield box, and Motorblock in three dimensions. To enhance the stability at high Reynolds numbers, various upwind-type schemes are developed. Free-slip and no-slip boundary conditions are also discussed.