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Casting Simulation For Your Foundrys

Profitability Using Hybrid Method Software.
ABSTRACT:

followed in foundries, i.e.

trial and error method, lots
of money, energy and time
are wasted.
Even then
process is not controlled
accurately. Foundries mostly
follow lot of heuristics which
they come out with their
experience in that casting.

The present work aims

at introducing simulation at
all stages of casting to
reduce
defects
and
increasing the productivity
and
profitability
of
the
foundry. The work presents
the simulation of a casting
using FDM software and
various plots of the casting.
The work describes the
various
stages
and
predictions involved with a
complex casting simulation.
The journal also presents the
detail about mathematics
involved in it.

Process operations and

casting are to be controlled
in a very accurate fashion.
One of the approaches that
can be adopted is simulation,
which is now becoming a
part
of
every
industry.
Computer
aided
casting
simulation
helps
us
in
visualizing the real world
environment casting process
in a mere few steps of
inputs.

KEYWORDS: Casting,
Casting
simulation,
FDM
simulation, SOLIDCast.
INTRODUCTION:

Simulation has become

an important tool in almost
in all foundries. Simulation
plays a major role in all
casting stages. The main aim
of all the foundry makers will
be to produce profitable and
high quality components to
survive in this competitive
era. This may be one of the
reasons why now a days
simulation has become an
unavoidable part of casting
production.

On
estimating
the
defects
in
the
casting
components major portion is
because
of
the
design
problems and minor portion
is caused by manufacturing.
The cost involved is also very
high.
Casting
process
simulation and analysis for
various defects is considered
to be one of the major
productivity tools.
Considering
conventional

the
approach
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The Shortening of lead

times,
producing
higher
quality and improving yield
of the casting, Simulation
can
be
used.
Casting
simulation eliminates shopfloor trials and achieving of
desired quality is made
easier. Casting simulation
requires domain knowledge,
and must be fast, powerful,
easy to use and accurate.

And also quite often it is

required to design to risering
and gating designs which
were not originally part of
casting design. If the ability
of the product to be cast is
already
checked
and
optimized already in the
design stage, a lot of useless
works can be avoided.

Opticast
Simulation.

SIMULATION:
The computer aided
analysis is carried out by
using a Finite Difference and
vector
modulus
based
Software,
SOLIDCast.
SOLIDCast is a PC based tool
that is used for simulating
the pouring of hot metal of
virtually and casting alloy
into
the
sand,
shell,
investment, or permanent
molds, and the subsequent
solidification
and
cooling
process.
The
analysis
preceded in three stages.

Solidification simulation
uses FDM based method of
heat
transfer
calculation
combined with a unique
3D CAD MODEL
tracking
of
volumetric
changes
in the metal, to
STL FILE
predict the temperature and
IMPORT TO CAE
volume
changes in a casting
ENVIRONMENT
as it is poured, solidified and
RUNNER
cooled.
DESIGN
MATERIAL

FINITE ELEMENT
FlowCast
is MODEL
a
full SYSTEM
featured MESH
CFD
simulation, INPUTS
based in the navier stokes
MESH
WEIGHTS
equations
for fluidCALCULATION
flow.
GENERATION

OptiCast is a optimizing
VIEW FACTOR
MOLD DATA
methodology
followed
to
CALCULATION
INPUT
optimize
the
considered
casting START
process
with
100% CASTING
SINGLE CYCLE
considering
the parameters &RISER
SIMULATION
of
design
variables,
constraints
and objective
FLOWCAST
SIMULATION
function.

is

Solidification
Simulation

The
CASTPIC PLOTS
following flow
chart CHECKING
gives
FOR

FlowCast
simulation

NO! ACCEPT

DEFECTS
YES! REJECT

REDESIGN

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the steps followed in the

experimental simulation of a
casting using SOLIDCast.
Pattern
Aluminum
Type
plate

of

material:
pattern:

Match

Type of mold: Silica sand.

Pouring
temperature:
1400-1450C
Theoretical Pouring Time:
6.67 s.
Table-1:
composition
S.
No.
1
2
3
4
5
6
7

Element
Carbon
Silicon
Manganes
e
Sulphur
Phosphoru
s
Chromium
Copper

Metal
Percent
age
3.3
1.9
0.7
0.1
0.15
0.4
0.4

PARAMETERS
CONSIDERED:

MODEL DETAILS
FOR STUDY:

The
analysis
is
governed by set of equations
for continuum of mass and
energy.
Fluid
flow
is
governed by Navier stokes
Equation.

TAKEN

Component
for
study:
Clutch housing of 407 tractor
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is imported to the SOLIDCast

environment. System and
required parameters are to
be specified.

(1)
P= RT (2)
R

= (

DISCRETISATION:

)/L

Finite
difference
method of discretisation is
followed over a complex
physical
domain
to form
a

(3)
Name of the alloy,
thermal conductivity, specific
heat,
density,
initial
temperature,
solidification
temperature, freezing range,
latent heat of fusion are all
the MATERIAL PARAMETERS
to be specified.
Types of mold, initial
temperature,
thermal
conductivity, specific heat,
density
are
the
MOLD
PARAMETERS need to be
specified.
SOLIDIFICATION POINT
AND NIYAMA CRITERION is to
be specified.
Values
for
HEAT
TRANSFER COEFFICIENTS are
also to be specified.

computational domain. The

discretised model may have
millions of cubes, and the
heat transfer equations are
applied to each cube, over
and over. Heat Transfer
Equations
applied
and
iterations are carried out
over the domain till the
solution converges.

The flow chart given in

fig.1 gives the steps involved
in simulation.
EXPERIMENTAL
SIMULATION:
A
complex
3D
dimensional
model
is
considered for simulation
and to plot the required
results. STL file of the model
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PHYSICAL DOMAIN:

by a process of applying
View Factor calculations to
the mesh. The View Factor
Calculation
takes
into
account the visibility of all
mold surfaces to all other
mold surfaces as well as the
surrounding
environment,
and adjusts the conditions at
each surface accordingly.
View factors are applied to
every surface in contact with
ambient conditions, so it
doesnt matter if the mold is
created as a part of the
model, or by meshing.

COMPUTATIONAL
DOMAIN:

SOLIDIFICATION
SIMULATION:
The equations given
below gives the applied heat
transfer equations and the
equation for temperature
prediction at the final node.
The accuracy of the results
of
numerical
simulation
depends upon the size of the
mesh,
material
property
data, and the heat transfer
coefficients specified for the
mold interface.
Q = [ KA(Tn1-T n2)(t/x) ] .
(4)

SOLIDCast
runs
the
filling analysis and followed
by solidification analysis.
(Fig.3
and
Fig.4).
Solidification
simulation
enables visualization of the
last freezing regions or hot
spots. This facilitates the
placement and design of
risers and risering aids in
order to increase yield while
ensuring casting soundness
without expensive and time
consuming trial runs.

Q = hA(Tn1-T n2) t .(5)

FLOWCAST SIMULATION:

Tf = Ti + Q/Vc .(6)

FLOWCast
allows
visualizing the flow of molten
metal
through
gating
systems and filling the mold.
FLOWCast,
Models
conduction, convection and
radiation in the mold cavity,

VIEWFACTOR
CALCULATION:
The variations in radiant
heat loss can be simulated
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allowing to analyze the

casting model and gating
design
to
predict
and
minimize flow related defects
such as misruns due to
premature solidification, or
oxide formation, or mold
erosion due to excessive
velocities during filling .
FLOWCast enables to view
progressive
temperature,
fluid velocity, and fluid
pressure during the fill, from
any angle of view.
_

to the Solidus Point. This can

help to locate isolated areas
of molten metal within the
casting and to get a general
idea
of
progressive
solidification in various areas
of the casting. The isolated
area is the area that is prone
to shrinkage. (Fig. 11).
CRITICALFRACTION
SOLIDIFICATION TIME:
Critical Fraction Solid
Time records the time, for
each part of the casting to
reach the Critical Fraction
Solid Point. This is the point
at which the alloy is solid
enough that liquid feed
metal can no longer flow.
Critical Fraction Solid Time is
generally a better indication
than Solidification Time. This
plot gives a good indication
of whether any contraction
that forms will be able to be
fed by liquid feed metal
within the risers or feeders.
The result critical fraction
solid time plot noted that
there are few isolated pools
of molten metal. (Fig. 13).

(7)
((v/t)+v.
v)
2
-p+ v+f .(8)

..(9)

..

(10)

..

TEMPERATURE GRADIENT

(11)

Temperature Gradient
is a measure of variation in
temperature
within
a
casting.
Temperature
Gradient is calculated at
each node within the casting
as that point hits the Niyama
Point on the cooling curve.

SOLIDIFICATION TIME
Solidification
time
shows the time, for each part
of the casting to become
completely solid, i.e., to cool
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Temperature Gradient can

be used to get an idea of
whether there was good or
poor directional solidification
at various points within the
casting. Higher temperature
gradients
are
good,
as
steeper
temperature
gradients mean a greater
driving
force
for
solidification. The brightest
areas indicate those areas
with the lowest temperature
gradients, and the poorest
directional solidification. (Fig.
14)

feed any area which is prone

to contraction, to avoid
shrinkage porosity in the
casting. (Fig. 16)

COOLING CURVES

SOLIDCast predicts well the

volume changes based on
theoretical calculations for
the behavior of iron and
graphite in the solidification
process.

Cast Iron is one of the most

complex alloys in terms of
how it solidifies and how
volume changes affect the
likelihood
of
shrinkage
porosity.
The example showed a
hypereutectic cast iron. In
this case, expansion starts
immediately
upon
solidification.(Fig. 12)

These curves describe

how a single point in a
casting behaves as it cools,
when its temperature is
plotted against time. As the
casting
loses
heat
(superheat) to the mold, it
cools down, remaining a
liquid until it begins to
solidify.
The
point
that
signifies
the
onset
of
solidification is called the
liquidus point. Once the
alloy is completely solid, we
say that it has reached the
Solidus
Point.
After
reaching this point, the
metal begins to cool more
rapidly as a solid. As the
casting solidifies, it gradually
changes from a fully liquid
material to a fully solid
material. We depend on the
flow of liquid feed metal to

NIYAMA CRITERION
Niyama has been used
extensively for shrinkage
prediction and directional
solidification
in
castings,
until the use of more
advanced calculations such
as the Material Density
Function.
Lower the value,
higher the probability of
shrinkage. Niyama criterion
plot (Fig. 12) shows little
shrinkage porosity in the
castings.
COOLING RATE
Cooling
Rate
is
a
measure of how quickly a
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casting is cooling down

measured at each point in
the casting as that point hits
the Niyama Point on the
cooling curve. Cooling Rate
can be an indication of
material quality. Areas of the
casting that cool rapidly
generally have a more
favorable grain structure,
with
less
deposition
of
partially-soluble compounds
at the grain boundaries. The
plot (Fig. 15) shows most of
the sections have the lowest
cooling rates.
HOT
SOLIDIFICATION

fill
material
/
casting
interface cells at the start of
the filling simulation, and
then at regular intervals
during the simulation. Each
one of the particles released
from each fill material /
casting interface cell is
tracked in time while the
filling simulation is executed.
The particles can be watched
while it moves during the
simulation, and also display
the particle movement after
a simulation is complete. The
plot (Fig. 9) shows the fluid
particle flow with respect to
time governed by navier
stokes equation (Eqn.8).

SPOT

Hot Spot plotting is a

function that locates thermal
centers or hot spots within
the casting by comparing
solidification times or critical
fraction solid times of points
within local areas. The range
of values is always 0 to 10,
and generally the value
plotted is around 1.1 or 1.2.

MODULUS
METHOD:

VECTOR

The method is useful for

the identification of hot spots
and the simulation of feeding
paths
accurately.
This
approach uses the direction
of
the
largest
thermal
gradient at any point inside a
casting to move along a path
which leads to a hot spot.

The hot spot plot (Fig. 10)

does not give an indication
of the severity of the defect,
as
it
does
not
take
contraction/expansion
into
account. But it gives a good
indication of areas which
may have problems.

Consider a section of casting

showing
iso-solidification
time contours

FLOW PATH LINES

FLOWCast releases a
group of particles from the
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For determining the

largest temperature gradient
at any point Pi inside the
casting, the vector modulus
method is followed. Fig. 17 &
Fig.18 shows the values
computed at two points
Pi(x,y,z).
CONCLUSION:

When the temperature Ti of

molten metal at a location Pi
reaches the solidus value,
the nearest location Pi+1
along
the
temperature
gradient is the one most
likely to supply Pi with liquid
metal
compensate
for
solidification shrinkage.

Casting simulation is
the mathematical way of
predicting a casting process.
The objective function of
maximizing
the
yield,
minimizing shrinkage and
minimizing solidification time
are all found to be greatly
achieved
using
Hybrid
method software. Simulation
should
become
an
indispensable tool in all
foundries, minimizing time,
energy spent and money,
thus maximizing profit. The
plot for various parameters
and defects very well gives a
good idea for redesign and
re-simulation done with no
cost of time. Casting process
simulation has become an
industry
standard.
No
foundry that produces high
quality castings can consider
simulation as unnecessary.

Pi , Pi+1 , Pi+2, Ph
represents the feeding path
in reverse.
The
approach
to
locating
hot
spots
and
tracing fluid metal flow paths
reduces the complexity of
computation by at least an
order magnitude as there is
no longer the need to
determine
temperature
exhaustively at all points
inside a casting.

REFERENCES:
1. Ravi.B, Srinivasan.M.N
(1990),
Hot
Spots
in
castings: Computer aided
location and experimental
validation
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2. Campbell, John, (2003),

The new metallurgy of cast
metals,
CASTINGS
(2ND
Edition),
ButterworthHienemann,
Burlington-MA
01803.

7.
Durgesh
Joshi,
Ravi
B(2007), Feedability Analysis
and optimization driven by
casting simulation, Indian
foundry journal.
8. Rundman B. Karl, Metal
Casting,
Reference
for
MY4130.

3.
Ravi
B,(2008),Casting
Simulation
and
optimization;Benefits,Bottlen
ecks, and Best practices.

9. Ravi B, Srinivasan M.N,

(1990)Casting solidification
analysis by vector modulus
method, International Journal
of Cast Metals.

4. ASM Handbook (1992),

ASM
International,
the
Materials
Information
Company.

10.
Heine,
Loper
&
Rosenthal (2005), Principles
of
Metal
Casting,
Tata
McGraw Hill, New Delhi.

5. Joshi D, Ravi B (2008),

Classification and simulation
based design of 3D junctions
in castings.

11. Anderson D. John, (1995),

Computational
Fluid
Dynamics, The Basics With
Applications, Tata McGraw
Hill Series.

6. Louvo Arno, M.Sc, CTCastech

Inc.
O.Y(1997),
Casting simulation as a trool
in concurrent engineering,
International
ADI
and
simulation conference.

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Fig.1 Meshed Model

Fig.2 Material properties

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Fig. 3 Mold Properties

Fig. 4 Weights calculation

Simulation Setup

Fig.

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Fig. 6 Filling simulation

Solidification simulation

Fig.

Fig. 8 FlowCast simulation

Fig. 9 Flow path lines

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Fig. 10 Hot spot plot

Solidification time

Fig.11

Fig. 12 Niyama criterion

Critical fraction solid point

Fig. 13

Fig.14 Temperature Gradient

rate

Fig.

14

15

Cooling

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Fig. 16 Cooling curve

Fig.17&18 point values using vector modulus method

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