Abstract
This paper presents a technique for automatically approximating casting shrinkage cavity models and its application in finite element analysis. First, reverse engineering was utilised to obtain the stereolithography format models of internal shrinkage cavities. After that, an in-house python code was used to analyse the shape of shrinkage cavity and then decompose it to ellipsoids, whose volume sum covers all points of the given shrinkage cavity obtained with reverse engineering. Finally, the ellipsoids were merged into a single ellipsoidal blob shaped three-dimensional computer aided design model, which can be used to model the casting with internal shrinkage for finite element analysis. The code was developed and implemented into ABAQUS as a customised plug-in toolkit, which makes it easy for engineers to model the casting with internal shrinkage cavities.
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