Simulation-enabled casting product defect prediction in die casting process

Abstract

In current casting industries, product development paradigm is shifting from traditional trial-and-error in the workshop to CAE-enabled simulation and ‘proof-of-concept’ by computer. The product development paradigm shift is thus from heuristic know-how and experience to more scientific simulation, evaluation, analysis and calculation. CAE simulation plays an important role in the new product development paradigm as it models the entire casting process and reveals the dynamic behaviour of the casting system in working conditions. In addition, the product quality panorama and product defects are explored via simulation in such a way that the root-causes of casting defects are pinpointed and the solutions to avoid them can be determined. In this paper, the CAE technology for casting process simulation is presented. The modelling of the casting process is first articulated and the detailed simulation issues are then described. The information related to the filling and solidification process and after-ejection behaviour are revealed by CAE simulation. Through case studies, how the CAE simulation helps identify and predict the process-related defects is illustrated and its efficiency is finally validated.