| CASTING INDUSTRY |
|
| Computer-Aided Engineering (CAE) Simulation of Casting |
| Objectives |
| To
Provide: |
- A comprehensive computer-aided engineering (CAE)
capability
- A design software for foundry engineers
- Castings with:
- Improved quality
- Reduced cost
- Coupled with foundry engineer's experience
|
| Casting Simulation for Design |
| Experimental
Methods |
- Pour & Pray ->Pour & Pray ->Pour &
Pray
(Delayed & costly)
|
| Casting
Simulation |
- Simulation ->Understanding ->Design Change
->Pour & Test
- Process parameters
- Mold geometry
- Pinch-off gating
|
- Porosity risering
- Cold shuts chills
- Misruns paddings
- Etc., (Better castings, less costly)
|
Factors Affecting Casting Mold
Design
|
- Mold Cavity
- To represent final component shape
- Cores
- To define internal shapes
- Sprue, Runner and Ingate Systems
- To fill mold cavity
|
- Risers
- To compensate shrinkage of solidifying
metal
- Chills
- To promote directional solidification
|
| The Finite Element Method for Engineering Problems |
- The most general numerical method
- Elements in the form of hexahedrals fill the solution
domain
- Set of simultaneous equations are solved
- Systematic in nature
|
- Models problems with:
- Complex irregular geometries
- Non-linearities
- Time-dependencies
- Complex boundary & initial conditions
- Interfaces with CAD systems
- Interfaces with stress analysis programs
|
| CAE Casting Simulation |
| Steps |
- Prepare a geometric model of the casting
- Prepare a finite element mesh
- Define material properties
- Define boundary and initial conditions (process
conditions)
- Perform filling & solidification analyses
- Graphically visualize results and model conditions
- Identify problem areas
- Activate the expert system application, "casting
advisor" for defect diagnosis, and remedy
- Modify geometry, material, and process conditions and
repeat steps 1 through 8
|
