Simulation in casting design

Simulation in casting design19.11.2015 CastingsAll models are wrong, but some are useful.George E.P. BoxWhy simulate?Full control of production processes:Moulding and core shootingMould/Die preparationPouring/fillingSolidifaction/coolingMicrostructures?ShakeoutResidual stresses?Heat treatment/Distortion

DESIGN & VALIDATEWhat is this all based on?Finite Element Method (FEM)CAD-modelsFEM meshing

Fluid dynamicsMelt behavior

Heat transferMaterial models

Gating/Running/FillingFilling moulds as fast as possible fully filled! As calmly as possible no turbulent flow defects!

Finding the optimal parameters with simulation

Filling

Solidification optimizationSolidifying material contracts need for additional feed material

Feeding optimization

Feeding effectivity

In shortMaking tooling and casting parts that are defective is costly!

Simulation can be used to:

VALIDATE designs based on theoretical principlesIDENTIFY problematic areas, e.g. mass concentrationsREDUCE the need for practical casting tests

CONTROL PROCESS CONTROL QUALITY