Abstract
This paper describes and validates a methodology for implementation of full-scale sand-casting simulation in a general-purpose finite element software, including mold filling, heat transport, solidification kinetics, chemical microsegregation and prediction of microstructure and material properties. The solidification model, customized for gray cast iron, includes novel methods for handling interaction between parallel dendritic and eutectic solidification modes and its impact of their interaction on the final microstructure. The validation involves a previously published gray iron casting experiment and involves comparison of simulated and experimental cooling curves, microstructure parameters and tensile strength. We believe that this is valuable to researchers and engineers seeking to improve the state of the art of casting simulation tools.
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