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Features of Using Programs for Casting Processes Modeling

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DOI: 10.1007/978-3-030-90318-3_3

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Book Title Software Engineering Application in Informatics
Series Title
Chapter Title Features of Using Programs for Casting Processes Modeling
Copyright Year 2021
Copyright HolderName The Author(s), under exclusive license to Springer Nature Switzerland AG
Author Family Name Kukartsev
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Given Name Viktor
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Organization Siberian Federal University
Address Krasnoyarsk, Russia
Email
ORCID http://orcid.org/0000-0001-7988-4766
Author Family Name Kaposhko
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Given Name Inga
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Organization Siberian Federal University
Address Krasnoyarsk, Russia
Email
ORCID http://orcid.org/0000-0001-9607-2866
Author Family Name Kukartsev
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Given Name Vladislav
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Division
Organization Siberian Federal University
Address Krasnoyarsk, Russia
Division
Organization Reshetnev Siberian State University of Science and Technology
Address Krasnoyarsk, Russia
Email vlad_saa_2000@mail.ru
 ORCID http://orcid.org/0000-0001-6382-1736
Corresponding Author Family Name Tynchenko
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Given Name Vadim
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Organization Siberian Federal University
Address Krasnoyarsk, Russia
Division
Organization Reshetnev Siberian State University of Science and Technology
Address Krasnoyarsk, Russia
Division
Organization Marine Hydro-Physical Institute, Russian Academy of Sciences
Address Sevastopol, Russia
Email vadimond@mail.ru
ORCID http://orcid.org/0000-0002-3959-2969
Author Family Name Leonteva
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Given Name Anna
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Organization Siberian Federal University
Address Krasnoyarsk, Russia
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ORCID http://orcid.org/0000-0002-4728-4683
Author Family Name Kartsan
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Given Name Igor
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Organization Marine Hydro-Physical Institute, Russian Academy of Sciences
Address Sevastopol, Russia
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Organization Sevastopol State University
Address Sevastopol, Russia
Email
ORCID http://orcid.org/0000-0003-1833-4036

Abstract The article provides information on existing modeling program systems, their brief description and ability
of practical application. A comparative analysis of the advantages and disadvantages of such simulation
 systems, which allowed in the framework of the tasks to reduce the number of systems under study to two
were carried out. The calculation of the sprinkling system for casting from the alloy 20X5ML of the
compressor wheel based on its model unit is performed, while using the LVMflow modeling program, its
most effective version of such a system was found. It is designed for the yield of suitable, the materials are
selected to obtain the required chemical composition of the alloy, based on the condition that the smelting
will be made on return and raw materials, the costs of their acquisition are determined. Further, this
calculation option was used as the original for modeling in the Procast program, which made it possible to
obtain more higher prime yield with suitable costs for raw melting stock.
Keywords Casting modeling - Gating system - 20X5ML alloy - Prime yield - Melting stock - LVMflow - ProCAST
(separated by '-')
 Features of Using Programs for Casting
Author Proof

Processes Modeling

Viktor Kukartsev1 , Inga Kaposhko1 , Vladislav Kukartsev1,2 ,

Vadim Tynchenko1,2,3(B) , Anna Leonteva1 , and Igor Kartsan3,4
1 Siberian Federal University, Krasnoyarsk, Russia
2 Reshetnev Siberian State University of Science and Technology, Krasnoyarsk, Russia
3 Marine Hydro-Physical Institute, Russian Academy of Sciences, Sevastopol, Russia
4 Sevastopol State University, Sevastopol, Russia

Abstract. The article provides information on existing modeling program sys-

tems, their brief description and ability of practical application. A comparative
analysis of the advantages and disadvantages of such simulation systems, which
allowed in the framework of the tasks to reduce the number of systems under
study to two were carried out. The calculation of the sprinkling system for casting
from the alloy 20X5ML of the compressor wheel based on its model unit is per-
formed, while using the LVMflow modeling program, its most effective version
of such a system was found. It is designed for the yield of suitable, the materials
are selected to obtain the required chemical composition of the alloy, based on the
condition that the smelting will be made on return and raw materials, the costs of
AQ1 their acquisition are determined. Further, this calculation option was used as the
original for modeling in the Procast program, which made it possible to obtain
AQ2 more higher prime yield with suitable costs for raw melting stock.

Keywords: Casting modeling · Gating system · 20X5ML alloy · Prime yield ·

Melting stock · LVMflow · ProCAST

1 Introduction

The most important task of modern production of semi-finished products and products
from foundry alloys is to reduce their labor intensity and an increase in the use of metal
utilization. One of the ways to increase the coefficient of use of the metal is to apply
modeling program systems.
Computer simulation becomes an integral part of the design processes of new parts
and the design of the technological processes of their manufacture [1, 2]. It acquires the
status of an important, and often decisive competitive advantage. Increasingly, customers
on the foundry in the list of requirements for the manufacturer of this product put forward
a requirement for the mandatory use of computer simulation [3, 4]. The advantages
provided by the automated modeling systems of casting processes (AMS LP) are obvious.
First of all, it is the possibility of working out the nuances of the foundry technology on the
virtual prototype of the casting manufactured, which reduces or completely eliminates

© The Author(s), under exclusive license to Springer Nature Switzerland AG 2021

R. Silhavy et al. (Eds.): CoMeSySo 2021, LNNS 232, pp. 1–8, 2021.
https://doi.org/10.1007/978-3-030-90318-3_3
 2 V. Kukartsev et al.

the need for test castings, reduces the process of designing the technology and reduces
Author Proof

the cost of castings. Visualization of the physical processes of foundry technology, such
as filling by the mold, cooling and solidification of the metal, its warping under the action
of thermal stresses makes it possible to better understand the features of these processes,
and consequently, to more effectively manage them in order to reduce the marriage of
castings and increasing the yield [5, 6].
To date, countries, the developers of the most common programs for modeling casting
processes are Germany, France, USA, England, Finland and Russia. Brief available
information about programs offered by these countries is presented in Table 1 [7–11].

Table 1. Foundry modeling programs.

Program name Developer Developer Functions Solving Minimum

country method price for 1
workplace,
Euro
Magmasoft Germany MAGMA GmbH HTSM FDM 65000
WinCast Germany Simtec Inc HTSM FEM 65000
Procast France ESI Group HTSM FEM 60000
PAM-CAST France ESI Group HTSM FDM 30000
Flow3D USA Flow Science HTS MCV 28900
SolidCast USA Finite Solutions Inc HTO FDM 26500
CastCAE Finland CT-Castech Inc. HTO FDM 15000
Oy, Espoo
LVMFlow Russia CJSC NPO MKM HTS MCV 29500
Poligon Soft Russia Sisoft Polygon Plus HTSM FEM 34600
Mavis-Flow United Alphacast HT FDM 11000
Kingdom Software, Swansea,
UK

Programs are characterized by the following possibilities:

• H - conducting the hydrodynamic calculation of filling the melted form.

• T - calculation of temperature fields during crystallization and detection of shrinkage
defects.
• S - calculation of stresses in casting and residual deformation.
• M - structure modeling (grain structure, ferrite and perlite distribution, graphite
inclusions size, etc.).
• O - parametric optimization of the grieving system in automatic mode.
 Features of Using Programs for Casting Processes Modeling 3

The programs use the following methods for solving the simulation of casting
Author Proof

processes:

• FDM - method of finite differences.

• FEM - method of finite elements.
• MCV - method of control volumes.

In Russia, today, the following modeling programs are widely spread:

• Magmasoft at 15 enterprises.
• WinCast at 3 enterprises.
• Procast at FSUE MMPP Salute (Moscow).
• SolidCast at OJSC Rostov Foundry Plant (Rostov-on-Don).
• LVMflow at 67 enterprises and 17 educational institutions.
• Poligon Soft at 8 enterprises and 10 educational institutions.

2 Materials and Methods

As a rule, a technology technologist uses the simulation program to verify the developed
variant of the manufacture of casting. First of all, it determines the place of education of
shrinkage defects and is looking for an option to eliminate them. Since the market dictates
its own conditions for the execution of orders, this work technologist must fulfill this
operation for 1–2 days (otherwise the favorable order will go to another manufacturer).
This is especially true of the manufacture of castings from alloyed steels of complex
configuration, the cost of which is high enough (at least 500 rubles/kg). For this reason,
the enterprise has a serious task of choosing the necessary modeling program [12].
As practice shows, the best results are provided by the programs Poligon, ProCast,
WinCast, which allow you to maximize the geometry of casting and identify even minor
defects. However, the complexity of the application of method for solving the casting
processes problem - FEM, leads to the preparation of the source data for computer
modeling can take several days and even weeks for 1 calculation. In addition, it requires
highly qualified personnel. For this reason, the mass distribution of foundry programs
using the FEM, in Russia did not receive.
Today, the ProCast program has been successfully operating on FSUE Salyut, where
the computer aided design (CAD) department was created, which completely optimizes
the process of obtaining responsible castings, spending, at the same time, about a month
per casting [13, 14].
In Russia, the only development that uses the FEM is the program Poligon, which is
also very difficult to use and significantly more expensive programs that apply FDM. For
many parameters, this program can be considered as a Russian analogue of the ProCast
system. However, practical application at the foundry enterprises of Russia showed that
the program Poligon cannot act as a daily program for the development of the technology
of obtaining castings. The complexity of use, the duration of obtaining results, as well
as the lack of qualified personnel, has reduced its use in ordinary enterprises to zero.
This was also influenced that the duration of the training for using Poligon in production
conditions ranges from six months to a year.
 4 V. Kukartsev et al.

The method of control volumes combines the simplicity and factorization of FDM,
Author Proof

as well as a good approximation of boundaries between different materials and various

phases. This allows modeling as quickly as possible without losing the accuracy of
calculations. LVMFlow is the only full-fledged foundry that uses this method and greatly
wins among these programs in capabilities, has a Russian interface and a domestic
database [15, 16]. In addition, the duration of learning to work with AMS LP LVMFlow
does not exceed 16 h, after which the technologist can begin to independently simulate
the casting processes.
Thus, the choice of a modeling program systems for an enterprise is a serious task
affecting the preparation of the production of castings.

3 Experimental Results and Discussion

As part of the study, the adjustment of the grieving system (GS) was performed for
casting from steel 20X5ML using LVMFlow and ProCast modeling programs. Then,
based on the achieved prime yield, the material costs for raw charge materials were
determined.
As an example, the casting of the compressor wheel with weight of 84 g was modelled
(Fig. 1a).

Fig. 1. Compressor wheel and model unit: a - compressor wheel; b - model block.

Considering the complexity of the configuration and the need to obtain sizes with
minimal processing allowances, a method for manufacturing castings on smelt models
was chosen. Using a methodology developed by M. L. Henkin, which provides the
metal supply to the most massive casting nodes, the gating system of 1st type was
calculated, and the model block was built with the following dimensions: diameter of
the riser is 30 mm, feeder length is 8 mm, feeder diameter is 12 mm (Fig. 1 b.). As an
initial, the simplest scheme of castings around the rising was accepted. The central risker
serves as the basis for the creation of an integrated mechanized technological process of
production of small castings. The use of a unified metallic frame as a supporting structure
provides the convenience of link assembly of the model block and its high strength in
the manufacture of the shell form. Already in the cast block, the central riser is securely
fixed in the fixtures of the machines when cleaning and cutting the castings.
 Features of Using Programs for Casting Processes Modeling 5

According to the sizes, a casting model with a spree-eating system was built in the
Author Proof

SolidWorks program and the prime yield was calculated as 32.98%.

The formation of castings is a very complex process, so it is almost impossible to take
into account all the factors affecting the crystallization process. Experimentally work
out all the options for LPS for finding the best is a complex and long-term process. As a
rule, the development of the most efficient version of the gating and supplying system to
obtain an experimental casting takes several weeks, so to determine the correctness of
the developed spruce system we applied the LWMFlow modeling program. The result of
modeling has shown that the calculated maritime system does not provide a non-defective
fill (Fig. 2a).

Fig. 2. Modeling results: a - defects detected during modeling in LWMFlow based on the initial
grieving system; b - section of castings in a block showing the absence of defects (modeling
in LWMFlow); c - modeling in ProCast with the sizes of the grieving system taken from the
LWMFLow program; d - final result of modeling in the Procast program.

After a set of unsuccessful fillings, it was decided to change the design of the grieving
system, including the location of the castings. As a result, it was possible to choose the
most efficient variant of the spree-supplying system (Fig. 2b) with a riser diameter equal
to 40 mm and a length of 320 mm. The prime yield was 30.76%.
The next stage of work was to carry out modeling using the ProCast program. The
source data served as the results obtained using the LWMFlow program. Figures 2c and
2d show the results of this study.
After automatic optimization of the grid and 3D models of the casting, it was possible
to reduce the diameter of the riser to 27 mm and its length up to 310 mm, which made
it possible to increase the technological prime yield from 30.76% to 31.92%.
 6 V. Kukartsev et al.

Further, on the basis of the obtained values of the outdoor casting, the metal balance
Author Proof

required for the release of the “compressor wheel” cast was made of steel 20X5ML
(Table 2).

Table 2. Estimated metal balance.

Balance item Technology using LVMflow Technology using ProCAST

program program
% kg % kg
Prime yield 30.86 1000 31.92 1000
Spoilage 4 129.618 4 125.313
Gates 58.64 1900.19 57.58 1803.88
Plums and splashes 2.5 81.011 2.5 78.3208
Irrecoverable losses 2 64.8088 2 62.6566
Waste 2 64.8088 2 62.6566
Metal filling 100 3240.4407 100 3132.83208

The balance of the metal is of great technical and economic importance. The con-
sumption of metal, the cost of liquid metal and castings depend on it. The following
indicators are of decisive importance: the type of melting unit and the technological
level of production. When a new casting is launched into production, such indicators as:
scrap of castings, waste (for induction furnaces), irrecoverable losses, waste and scrap
are set based on those achieved in a similar production.
Having a balance of metal, we make the choice of charge materials, proceeding from
the condition that the smelting will be carried out in an induction furnace with an acid
lining, with full use of the return [17, 18]. The choice of materials is carried out in such a
way that the chemical composition of the resulting alloy for each element has an average
(permissible) value and meets the requirements of Russian State Standard (GOST) for
steel 20X5ML. To do this, we calculate the charge using the selection method, which
allows us to determine the required combination of starting materials. After that, we
move on to determining the consumption of the selected charge materials and the cost
of purchasing them. The results are shown in Table 3.
 Features of Using Programs for Casting Processes Modeling 7

Table 3. Calculation of costs for raw batch materials (per one ton of prime yield).
Author Proof

Name of GOST or Price, Consumption and costs at Consumption and costs at

material specification rubles prime yield of 30.86% prime yield of 31.92%
/ kg % kg Rubles % kg Rubles
Scrap 15X5 20072-74 20 32.5 1053.1 21 060 33.5 1049.5 20 990
Chrome 5905-2004 730 1.7 55.2 40 300 1.79 56.09 40 950
metal X99
Manganese 6008-90 140 0.186 6.04 850 0.185 5.84 820
metal Mn 998
Silicon 2169-69 140 0.188 6.07 850 0.194 6.1 854
metallic Cr 0
Molybdenum TU 48-19-73-86 5500 0.217 7.04 38 740 0.186 5.84 32 140
metal MSh-2
Electrode TU 70 0.062 1.995 138 0.063 1.986 139
break, grade 1911-109-73-2000
A
Total costs of raw materials 101 938 95 893

4 Conclusion
The calculations show that when using the ProCAST casting process modeling program
for developing a gating-feeding system, in comparison with the LVMflow program, it
saves the cost of purchasing raw materials in the amount of 6045 rubles per 1 ton of
suitable alloy steel 20X5ML. This enables the foundry to successfully compete in the
market for castings from the specified alloy, at the expense of reducing their cost.
Thus, the article showed how the correct choice of a casting process modeling system
can affect both the quality of such a process itself and the final cost of products and,
accordingly, the competitiveness of an enterprise in the market.

Acknowledgements. This article was prepared as part of a research carried out with the finan-
cial support of the Russian science Foundation according to the research project No. 19–71-
00028 within the framework of the Competition of 2019 “Conducting initiative research by young
scientists”.

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