Mold design optimization and quality assessment of steel castings through integrated simulations and experiments

Abstract

The quality of steel castings was analyzed in this paper through integrated simulations and experiments. The standard tensile specimens were considered as actual cast products. These specimens were prepared using a multi-cavity mold which was initially designed using standards and foundry practices followed by its optimization in casting simulation software MAGMA Soft. The specimens produced with the optimized mold were then tested under tension until fracture. Porosity predicted in casting simulations was integrated to finite element simulations of tensile testing. Simulated and experimental results were compared, discussed, and conclusions drawn. Some specimens indicated discrepancy in the simulated and experimental stress-strain behavior; however, porosity was not found responsible for this disagreement as confirmed through X-ray imaging and by comparing the simulated and actual porosities. It is concluded that the quality of cast specimens is compromised due to ineffective heat treatment which should be done in a more controlled manner for improved quality and performance of castings produced using multi-cavity molds.