Simple Simulation Study Chapter 9

CHAPTER 9

SIMPLE SIMULATION STUDY

To minimize the risk of casting defects like porosity and shrinkage in the final product,
a casting simulation study was conducted using Altair Inspire Cast software. This simulation
aimed to optimize the gating system design and predict solidification patterns for the
component.
9.1 ABOUT THE SOFTWARE

Altair Inspire Cast is a software program designed specifically for casting

simulation. It helps engineers and designers predict and optimize the casting
process for various components. Here's a quick breakdown of its key features and
benefits:
9.1.1 User-Friendly Interface: Inspire Cast boasts an intuitive and easy-to-
use interface, making it accessible to both beginners and experienced users
in the field of casting simulations.
9.1.2 Streamlined Workflow: The software follows a well-defined, five-step
workflow that guides users through the entire simulation process efficiently.
This includes defining the part geometry, setting up casting parameters,
simulating the process, analyzing results, and optimizing the design for better
outcomes.
9.1.3 Casting Process Variety: Inspire Cast can simulate different casting
processes commonly used in manufacturing. This includes gravity casting,
sand casting, investment casting, and even high-pressure die casting
(depending on the software version).

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9.1.4 Gating System Optimization: The software allows users to design and
analyze various gating system configurations. By simulating metal flow within
the mold, engineers can identify the most efficient gating system to minimize
turbulence, improve filling, and reduce casting defects.
9.1.5 Solidification Prediction: Inspire Cast can predict solidification
patterns within the cast part. This helps identify potential issues like shrinkage
porosity or cold shuts, allowing for proactive design modifications to ensure a
sound casting.
It streamlines the simulation process, allowing engineers to gain valuable insights
and optimize casting parameters for successful production.

9.2 SETTING PARAMETERS FOR SIMPLE SIMULATION ANALYSIS

Fig 9.1 Designing a CAD model of gating system

using Creo Parametric 6.0.6.0

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Fig 9.2 Importing the CAD model of gating system

to the simulation software

Fig 9.2 Defining the direction of gravity for the gating system

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Fig 9.2 Designating filling system which includes the pouring

basin,sprue,sprue base well,runner and ingates

Fig 9.2 Designating the risering system and neck

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Fig 9.2 Entering the pouring time parameters

Fig 9.2 Setting up the mold parameters

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9.3 FILLING ANALYSIS WITH TEMPERATURE DISTRIBUTION

The figures from 9. (a) to 9. () represent the filling analysis with temperature
distribution which shows the varyiation of temperature throughout the gating system
during filling,along with the legend for temperature distribution.

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