Casting Simulation Software Research Articles

Computer Simulation of Casting Process of Aluminium Wheels - A Case Study

Aluminium disc wheels intended for normal use in passenger cars are commonly produced by gravity casting. If the cooling process and the initial temperature of the mould are not well controlled, shrinkage cavity will occur after solidification, causing leakage in the disc wheel. In this research, a casting simulation software is used to simulate the casting process of aluminium wheels. The casting simulation is done iteratively until the mould temperature converges to a stable temperature. A ‘shrinkage index’ (SI) is defined to provide a quantified index of casting quality of aluminium wheels, based on the phenomenon of liquid entrapped at the joints of rim and spokes of the wheel where shrinkage cavity usually happens. This shrinkage index shows good correlation with the aluminium wheel leakage test results. This paper also discusses the influence of cooling process parameters on SI, including initial mould temperature, and geometry of the wheel, which verifies engineers' empirical data. This iterative simulation process and SI can be used to predict the casting quality of aluminium wheels and to find the optimal parameters of the casting process.

Numerical Study on the Low Pressure Die Casting of AZ91D Wheel Hub

Most magnesium alloy components available for automobile are made through die casting. In this paper, PAM-CASTTM, commercial die casting simulation software based on the finite difference method, is employed to simulate the low-pressure die casting process of magnesium wheel hub. The temperature field and velocity field during filling and solidification stages are analyzed; the evolution of temperature distribution and liquid fraction was numerically studied. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes are predicted. The cooling performance of mould during casting is also investigated. Via analyzing the shrinkage defects generated under various cooling conditions, the cooling system set in the side mould is found to be more effective for enhancing the cooling capacity at the rim/spoke junction areas. With this cooling system, the hot spots at the junctions are obviously reduced and product quality is improved.

Simulation-based selection of optimum pressure die-casting process parameters using neural nets and genetic algorithms

Pressure die-casting condition selection mainly relies on the experience and expertise of individuals working in production industries. Systematic knowledge accumulation regarding the manufacturing process is essential in order to obtain optimal process conditions. It is not safe a priori to presume that rules of thumb, which are widely used on the shop floor, always lead to fast prototype production calibration and to increased productivity. Thus, neural network meta-models are suggested in this work in order to generalise from examples connecting input process variables, such as gate velocity, mould temperature, etc., to output variables, such as filling time, solidification time, defects, etc. These examples, or knowledge, are gathered from experiments conducted on casting simulation software, which are designed systematically using orthogonal arrays (DoE). They could also be based on experiments from industrial practice. Neural models derived in this way can help in avoiding excessive numbers of what-if scenarios examined on the casting simulation software, which can be very time-consuming. Furthermore, they can be employed in the fitness function of a genetic algorithm that can optimise the process, i.e. yield the combination of input parameters which achieves the best output parameter values.

Casting simulation software and services

Casting simulation software and services

Numerical simulation of the casting process of titanium tooth crowns and bridges.

The objectives of this paper were to simulate the casting process of titanium tooth crowns and bridges; to predict and control porosity defect. A casting simulation software, MAGMASOFT, was used. The geometry of the crowns with fine details of the occlusal surface were digitized by means of laser measuring technique, then converted and read in the simulation software. Both mold filling and solidification were simulated, the shrinkage porosity was predicted by a "feeding criterion", and the gas pore sensitivity was studied based on the mold filling and solidification simulations. Two types of dental prostheses (a single-crown casting and a three-unit-bridge) with various sprue designs were numerically "poured", and only one optimal design for each prosthesis was recommended for real casting trial. With the numerically optimized design, real titanium dental prostheses (five replicas for each) were made on a centrifugal casting machine. All the castings endured radiographic examination, and no porosity was detected in the cast prostheses. It indicates that the numerical simulation is an efficient tool for dental casting design and porosity control.

Effect of cryogenic temperatures, vacuum and gaseous media on friction and wear of materials : V. F. Afanas'ev and G. S. Khimich, Soviet Mater. Sci., 2 (2) (1966) 152–154; 2 figs., 1 table, 8 refs. (Translation by Faraday Press, New York, of Fiz.-Khim. Mekham., Mater., 2 (2) (1966) 209–212.)

In the present study, the mechanical and metallographic properties of camshafts produced from chilled cast iron were examined experimentally and numerically relating with the solidification, cooling rate and metal flow. First of all, with the help of the 3-dimensional drawing and design programs the whole casting methodology was planned. This planning was analyzed with casting simulation software. After that camshafts were produced experimentally at the foundry. Chill material was used in order to get rapid cooling. The phases, dendrite structure and dendrite arm spacing on the lobes of camshaft were examined with an optic microscope and XRD. The Brinell, Rockwell and Vickers hardness tests were carried out on surfaces of lobes and camshafts. On the rapid cooling areas, the ledeburitic phase and high hardness values, on the slow cooling surfaces, rosette like graphite in pearlitic and low ferrite phase and low hardness values were examined. On the chill areas 2–15 μm DAS (dendrite arm spacing) were measured.