Seminar On

CASTING SIMULATION
INTRODUCTION
 Simulation is the process of imitating a real phenomenon
using a set of mathematical equations implemented in a
computer program.
 Metal casting subject to an almost infinite number of
influences.
• Geometry
• Material
• Process
Several researchers, worked and developed relevant equations,
and implemented them in computer programs.
Casting simulation programs

• AUTOCAST
•PROCAST
•SOLIDCAST
•MAGMA
•NOVA SOLID
•JS CAST
•CAST FLOW
•RAPID CAST
 Inputs to simulation
3D CAD MODEL OF THE CASTING.
MODIFICATION-
Removing holes that are created by machining (not by cores)
 Adding draft
Various allowances (shrinkage, machining, distortion)
 This is followed by the design and modeling of mould, cores,
feeders and gating system.
SPECIFICATION OF MATERIALS -cast metal, mould, core.
PROCESS PARAMETERS -type of mould, metal-mould heat
transfer coefficient, pouring temperature.
 Outputs of simulation
Animated visualization of mould filling, casting
solidification and further cooling at room temperature can
be simulated, which is useful for predicting
Microstructure
mechanical properties
residual stresses and distortion.

Mould filling simulation helps in predicting the total

filling time, mould erosion, incomplete filling and air
entrapment.

Casting solidification simulation shows the temperature

gradient and cooling rates inside the casting.
 TEMPERATURE GRADIENT

Visualization of filling, feedpaths,

cooling, and radiography
(Courtesy: AutoCAST)
DIFFERENT CASTING SIMULATIONS
 It can simulate moulding processes such as green sand,
chemically bounded sand, investment and permanent mould.
solidcast contains both gating and riser design tools that
allows to new casting in just few minutes.
With solidcast the user can import 3D model from
commercial CAD packages, or build own model without CAD.
Outputs are available with fully movable 3D MODELS, X-Ray
images, high-resolution color and windows video files.
 When is simulation necessary?
Simulation should be used when it can be economically justified
for at least one of the following three reasons:

Quality Enhancement by predicting and

eliminating internal defects like porosity.

Yield improvement by reducing the volume of

feeders and gating channels per casting.

Rapid development of a new casting by reducing

the number of foundry trials.
 Applications
① Casting Troubleshooting-
This is needed for existing castings that have unusually
high or unexpectedly varying level of internal defects
(mainly shrinkage porosity, sand inclusions, poor yield.)

②Part design improvement- Casting simulation can

point out features prone to defects. These can be
modified to prevent expensive remedial measures at
the foundry stage, such as additional feeders and
padding (additional machining) for the above two
problems. Minor changes to part design can
significantly improve its manufacturability without
affecting its functionality.
③ Method optimization:

Comparison of manual and computer-aided method optimization

Major stages in casting simulation and optimization
Several engineering colleges have set up casting simulation facilities
CONCLUSION
Casting simulation technology has sufficiently matured and has
become an essential tool for casting defect troubleshooting and method
optimization.
It enables quality assurance and high yield without shop-floor trials,
and considerably reduces the lead-time for the first good sample
casting.
The programs are gradually become more powerful, by including
method design suggestions, automatic modeling of feeders and gating
system, and user-guided optimization for achieving the desired quality
at the highest yield. In near future, we will be able to get the castings
right first time, every time, in real time.
References
 Technical Paper for Indian Foundry Journal January 2008 Special
Issue ‘Casting Simulation and Optimization: Benefits, Bottlenecks,
and Best Practices’ Dr. B. Ravi, Professor Mechanical Engineering
Department IIT Mumbai.
 Research paper on ‘Casting Simulation- Best Practices’ by Dr. B. Ravi
, IIT Mumbai.
 http://www.authorstream.com/Presentation/casting simulation
 http://www.wikipedia.org/wiki/casting_sumulation

Thank you