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Bracket-Casting Design Tutorial by Using Simulation

This document provides a tutorial on using simulation methods to design casting parts and gating systems. It describes a case study of designing risers and a gating system for casting six bracket parts. First, a solidification simulation was run to identify the proper size, location and number of risers needed to prevent shrinkage defects. Second, a mold filling simulation revealed that the initial gating design did not fill all cavities at the same time, so the choke areas were recalculated and resimulated until an optimized design with uniform filling was achieved. The key lessons were that simulation allows proper riser and gating design to be determined quickly and cost-effectively compared to trial and error methods.

Uploaded by

Peeka Prabhakara Rao
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© © All Rights Reserved
Available Formats
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81 views

Bracket-Casting Design Tutorial by Using Simulation

This document provides a tutorial on using simulation methods to design casting parts and gating systems. It describes a case study of designing risers and a gating system for casting six bracket parts. First, a solidification simulation was run to identify the proper size, location and number of risers needed to prevent shrinkage defects. Second, a mold filling simulation revealed that the initial gating design did not fill all cavities at the same time, so the choke areas were recalculated and resimulated until an optimized design with uniform filling was achieved. The key lessons were that simulation allows proper riser and gating design to be determined quickly and cost-effectively compared to trial and error methods.

Uploaded by

Peeka Prabhakara Rao
Copyright
© © All Rights Reserved
Available Formats
Download as PDF, TXT or read online on Scribd
You are on page 1/ 4

Casting design tutorial by using simulation method

Example: One
Date: March, 2010

Gating system is an important factor in the production of quality castings, therefore, should be
fully considered in the design and construction of pattern. This tutorial will explain how to do
specific steps for simulation to design the casting parts with highly accuracy without spending
too much time in production line.

Part name: Bracket


Process: Disamatic vertical molding
The number of cavity per mold: 6
Task: Gating system modification

Material:GGG50

Fig.1

First step: Solidification Simulation


Note: Solidification simulations help us to identify and Proper design of the risers (number, location, and size)

For every pair of parts 3 risers with 5 cm in diameter by 7.7 cm in height were applied.
With solidification simulation any defects related to solidification in cast part can be detected.
In fig 2, 3 the simulation results show the shrinkage and Liquid mapping of the process.

Fig.2

Liquid mapping

Fig.3 shrinkage is only in risers and


cast parts free of shrinkage

There is no shrinkage in cast parts, plus location and sizes of riser were selected properly. (The
next step might be optimization of the process: re-design the riser using simulation). Briefly, for
size and location of risers, these functions from SUTCAST solidification simulation should be
considered:

Module
Liquid mapping
Shrinkage
Thermal distribution

For more explanations, we recommended you to visit our solution pages in our website.

(www.sutcast.com)
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Second step: Mold filling Simulation

(checking the gating system dimensions)

Proper design of an optimized gating system will be made easier by application of fluid flow
simulation. For the reminding, to design the gating system we should consider the following
factors as priority:

Minimizing Turbulence
Rapid mold filling
Maximizing Yield
Removal slag, Dross, and inclusions
facilitate gating removal
Desire thermal gradients

It is important to fill every mold quickly, but turbulent flow needs to be avoided. Fig.4 shows
the initial structure of gating system for this part.

Fig.4 gating system

To speed up the calculation of gating systems and Design the appropriate choke,
Equation (1) can be used.
F (choke area)

G weight of molten metal


t 8 filling time)
h height (h1, h2, h3)
m 0.5 coefficient of friction)

By mold filling simulations the results at 3s and 5.5s time of filling (Fig 5 and 6), confirm that
this gating approach is not appropriated, because Some cavities are going to fill (vertical parted
molds as a guide) in less than 8 s (Bottom) and some after 8s (Top).
All of cavities should be filled by molten metal at the same time.

www.sutcast.com
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Fig5Fig6

To re-sizing chocks area and set up the filling time in upper and middle and lower cavities, we
can Re -calculate the F1, F2, F3 based on 8s seconds. It is important to know that the real
coefficient of friction (m) can be determined only after mold filling simulation. Once applied
changing, we run the mold filling simulation again to see how all of cavities are filling by molten
metal.
Fig 7 and Fig 8 show after 3s and 5.5s these confirmed all cavities are filled at the same
time.

Fig7Fig8
With application of simulation, we can optimize our design in the short period of time and
decreasing cost. Imagine how much cost is going to be if you rely on try and error method in
your production line.

www.sutcast.com
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Lessons learned:
The outputs from these simulations are:

The Mold filling and solidification of the designs were simulated using SUTCAST

Proper design (location, number, and size) of the risers can be determined from solidification
simulation
A predicted map of possible macro-shrinkage defects
The appropriate of choke and gating system can be determined quickly through fluid flow
simulation.

www.sutcast.com

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