Casting Simulation Software - Applications and Benefits

Casting Simulation Software – Applications and Benefits
B.Ramesh Chandra
Assistant Professor,
Department of Metallurgical Engineering,
JNTUH College of Engineering, Hyderabad, India.
Abstract: Methodology:
Casting simulation helps visualize mold filling and Figure1 shows a flowchart, in which 3D CAD and
casting solidification. It predicts related defects like simulation tools are utilized to improve the system
shrinkage, porosity and hard spots and optimize the design of the casting[2].
casting design to achieve the desired quality with high
yield. Flow and solidification of molten metals is very
complex difficult to simulate correctly by conventional
techniques. For industrial application, we need an
alternate approach that is fast, reliable and user-
friendly. In this paper emphasis is given on the casting
tools which help the foundry engineers to decide the
better simulation software.
Keywords:
Casting, Simulation, optimization, mold filling, casting
softwares
Introduction:
Simulation is the process of imitating areal
phenomenon using a set of mathematical equations
implemented in a computer program. A complete and
physically accurate simulation of metal casting process
is very difficult. The important to develop a practically
useful simulation program is to determine the most
important factor. Some of the well-known casting
simulation programs currently discussed [1].
The main inputs for the casting simulation process are:

(a) The geometry of the mould cavity (3D model of Figure 1: Shows a flowchart of a design process, in
the casting, feeders, and gating channels). which 3D CAD and simulation are used by the
(b) Thermo-physical properties (density, specific foundry.
heat, and thermal conductivity of the cast metal as
well as the mould material, as a function of From table 1, it introduce us the casting simulation
temperature). software which are used in foundry. It helps us in
(c) Boundary conditions (i.e. the metal mould heat many ways especially the mold filling time and
transfer coefficient, for normal mould as well as solidification time[3].
feed aids including chills, insulation and
exothermic materials). Table 1: List of casting simulation software’s:
(d) Process parameters (such as pouring rate, time Sl. No Name of casting software
and temperature). 1 SUTCAST
2 ProCAST&QuikCAST
3 FLOW-3D
4 MAGMASOFT
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5 SOLIDCast Use of this casting simulation will keep casting
6 OPTICast producers competitive & profitable. With this software
7 FLOWCast the casting process from filling to solidification is
simulated. Foundries relying on this simulation tool
Casting simulation software’s: can have the advantage of the latest casting process
In this section, the details of the casting simulation design technology that calculates residual stresses,
software’s are explained thoroughly. So that it may metallurgical prediction improves quality, reduces lead
help the foundry engineers to choose the right software times and cost.
for right applications [4-6].
(v) SOLIDCast:
(i) SUTCAST: It is the world’s most popular metal casting software &
It is one of the most powerful and user friendly tools solidification modelling software. The casting
for visualizing, modeling, analyzing, and optimizing simulation software offers accuracy, ease of use and
every foundry process. The software simulates the power.
molten metal of any casting alloy into sand or
permanent molds. The software developed to Benefits of this software are listed below:
accurately simulate the entire casting process and  It can simulate thermal changes caused by heat
provide quick and reliable solutions to casting transfer in the solidification process of casting
problems for any casting process and material needs. It  Visualize the solidification of casting process of a
provides mainly the Solidification Simulation and particular cast using this casting design simulation
Mold Filling Simulation. program.
 It can detect defects that might occur during the
(ii) ProCAST & QuikCAST: casting process.
It is a complete solution allowing predictive evaluation
of the entire casting process including filling and (vi) OPTICast:
solidification defects, mechanical properties and It is a casting optimization module which simulates the
complex part distortion. It enables rapid visualization casting design process, giving more accurate results in
of design changes and allows for correct decision- molding and solid casting. It works in integration with
making at an early stage of the manufacturing process. SOLIDCast and provides an automatic casting design
Using this software we can model the casting defects solution to engineers. Itanalyzes the size and properties
which are shown in table 2. of riser and gating components.
Table 2: Shows the casting defects which can be (vii) FLOWCast:

simulated using ProCAST and QuikCAST It is yet another exciting module which works with
SOLIDCast to simulate the flow of molten metals
(iii) FLOW-3D: when they are poured into the cast. This allows
It consists of a full flow and thermal solution for both engineers to visualize how different processes like
the cast alloy and the die or mold, providing detailed conduction, radiation and cavity filling work together
insights into the flow characteristics of a simulated to produce the final product. The software uses
casting. It can also enable modelers to save Computational Fluid Dynamics technology to simulate
unnecessary development costs when deploying new the flow of molten metal through cavities and casts to
casting processes or alloys. analyze how the metal will solidify. The mold filling
simulation software can be used with any kind of
(iv) MAGMASOFT: casting, including investment casting, iron casting,
It provides cutting-edge solutions that meet the needs copper castings, aluminum sand casting as well as steel
of casting producers. Casting simulation is the sand casting. This software comes with two modules
standard accepted for designing the casting process for modeling mold filling:
before producing expensive moulds or patterns.
Page 347
(a) Quick Simulation – This is a relatively fast process Sun and Su [12] suggested the numerical simulation
which can be used in the initial stages of a project, technique, parameters of gating and riser for a
as it helps industry engineers to simplify magnesium alloy casting with multiple analysis
assumptions and simulate the mold filling process characteristics in magnesium alloy base casting to
in a short amount of time. analyse the effect of various gating system designs on
(b) Full Simulation – The fill simulation feature of cavity filling and casting quality using MAGMASOFT
FLOWCast uses Computational Fluid Dynamics to simulation software; satisfactory results were obtained
calculate the fluid flow in different casts. The final with high yield and reduced shrinkage porosity.
output can be viewed from any angle and is Sutaria [13] worked on a new idea where optimization
computed based on a number of factors, including of casting feeding is done with the help of feed-paths.
progressive temperature, fluid velocity and fluid The computation of feed-paths is done by the method
pressure. known as vector element method (VEM).
Literature Review: Benefits of casting simulation:

There were lot of research work had been done The main uses for using different casting simulation
oncasting simulation by using different casting software’s are below:
simulation software’s. The literature review is mainly  Energy savings
focusing on design and optimization technique based  Improved product quality
on casting related defects and their research and  Less remelting and refinishing
outcomes. Ravi and Joshi [7] orked on computer-  Shortened lead time & increased production
aided casting design and simulation of feeder and  First Time Right
gating design of castings using Auto-CAST software  Predicting Metallurgy
and they describe how it assists in designing,
modeling, simulating, analyzing and improving cast CONCLUSION:
products. Bhatt and Barot[8] suggested that the design Casting simulation technology become a powerful tool
optimization of feeding sys-tem and simulation for casting defect troubleshoot in and method
reduced the casting defects of cast iron in foundries, optimization. It will reduce the lead time for the
which arose during solidification and mold filling. In sample casting; improved productivity and knowledge
casting processes most important is to change riser and of software’s can be maintained for future use and for
gates dimensions and simulate with the help of Auto- training new engineers in foundry. By using casting
CAST software. The simulation got shrinkage and simulation software’s one can avoid conducting trials
reduces hot spots and cracks in gear box of automobile on computers.
components.
References:
Masoumi et al. [9] suggested the effect of gating 1.B. Ravi, "Computer-Aided Casting- Past, Present
design on mold filling for light metal casting and Future," Indian FoundryJournal, 45(1), 65-74,
processes. The validation results showed that the 1999.
design and shape of the gate and the ratio of the gating 2.P. Prabhakararao, G.Chakaraverthi ―Application of
system have a great influence on the pattern of mold castingsimulation‖, International journal of
filling. Hassan et al. [10] investigated the impeller thermaltechnologies, Vol.1,No.1(dec-2011).
shaped casting using MAGMASOFT Software. The
effect of riser and gates on parameters, such as filling 3.Maria Jos Marques, ―CAE TECHNIQUES
pattern, pressure and speed, cooling rate, solidification FORCASTINGPTIMIZATION‖,, INEGI,P.4465-
and related defects, was studied. Choudhari et al. [11] 4591, 2006.
suggested that by optimization method cast-ing related
defects can be improved. The proper location, size and 4.H.C.Pandit and S.M.Ingale, ―Casting Optimization
design of gating and feeder system using simula-tion Aided By Simulation‖, International Conference on
technology improved the shrinkage porosity and SunriseTechnologies,13th – 15th Jan 2011, pp.4-7
cracksin casting.
Page 348
5.Richard W Heine, Carl R Loper and Philip C
Rosenthal, ―Principles of Metal Casting‖, Tata
McGraw HillPublication, 15th Edition, 1994, pp.11-
14.
6.S. Wetzel, ―Casting Process Modeling Round Up,‖

Modern Casting, 101 (9), 2011, p.7-9.
7.Ravi, B., Joshi, D., 2007. Feedability analysis and

optimization driven by casting simulation.Indian
Foundry J. 53 (6), 71—78.
8.Bhatt, H., Barot, R., 2014. A design optimization of

feeding sys-tem and solidification simulation for cast
iron. In: Proceeding on 2nd International Conference
on Innovations in Automation and Mechatronics
Engineering, vol. 14, pp. 357—364.
9.Masoumi, M.H., Hu, J., Hedjazi, M., Boutorabi, A.,

2005. Effect of gating design on mould filling
paper.AFS Trans. 05-152 (2), 1—12.
10.Hassan, I., Sheikh, A.K., Al-Yousef, A., 2012.

Mould design opti-mization for sand casting of
complex geometries using advance simulation tools.
Mater.Manuf. Process 27 (7), 775—785.
11.Choudhari, C.M., Padalkar, K.J., Dhumal, K.K.,

Narkhede, B.E., Mahajan, S.K., 2013. Defect free
casting by using simulation software. Appl. Mech.
Mater. 313—314, 1130—1134.
12.Sun, Zhizhong, Su, Henry, 2008. Numerical

optimization of gating system parameters for a
magnesium alloy casting with mul-tiple performance
characteristics. J. Mater. Sci. Technol. 18, 256—264.
13.Sutaria, M., 2010. Casting simulation case study:

shaft pin (cast iron-green sand casting).Indian Foundry
J. 56 (12), 5.
Page 349

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Casting Simulation Software – Applications and Benefits

The main inputs for the casting simulation process are:

Table 2: Shows the casting defects which can be (vii) FLOWCast:

Literature Review: Benefits of casting simulation:

6.S. Wetzel, ―Casting Process Modeling Round Up,‖

7.Ravi, B., Joshi, D., 2007. Feedability analysis and

8.Bhatt, H., Barot, R., 2014. A design optimization of

9.Masoumi, M.H., Hu, J., Hedjazi, M., Boutorabi, A.,

10.Hassan, I., Sheikh, A.K., Al-Yousef, A., 2012.

11.Choudhari, C.M., Padalkar, K.J., Dhumal, K.K.,

12.Sun, Zhizhong, Su, Henry, 2008. Numerical

13.Sutaria, M., 2010. Casting simulation case study:

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