Simulation in casting design 19.11.2015 Castings
Jan 18, 2016
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