Abstract
OptCast is an integrated thermal optimization tool coupling commercial casting simulation software with optimization software iSIGHT. Two types of optimizations are realized in OptCast: one uses an inverse modeling approach to determine boundary conditions such as interfacial heat-transfer coefficients (HTCs), and the other optimizes casting process variables by minimizing cycle time while maintaining casting quality. In this article, the global architecture and the development of OptCast for the commercial casting simulation software MagmaSoft is described. The determination of interfacial HTCs with OptCast for the casting process and the water quenching process is discussed. The optimized HTCs for a specific casting process are applied to a V8 engine block for thermal analysis with sufficient accuracy to enable prediction of microstructures and mechanical properties. The optimized HTCs for a water quenching process were applied to a cylinder head for residual stress analysis.
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