Casting Simulation : Component Name

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Roll No.:
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Work Integrated Learning Program

BIRLA Institute of technology and Science, Pilani
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Casting Model & Methoding

Spru
e

Mold

Cast

Riser
s

Method image

Sleeves

Core

Input parameters
Item

Component Name

Material

Material grade

Pouring Temperature

Temperature C

Pouring Time

Sec

Shrinkage allowance for Material

Mold Material

Mold Temperature

Sleeve

Sleeve temperature

Chill material
Chill temperature

:
:

(you can delete if you dont have any of these model, just write what ever is available with you)

Flow Simulation |
Temperature

Flow Image 5%

Beginning of the flow

Flow simulation shows filling percentage and flow time with the respective temperature plots,
above Figure shows the fill rate of % at a time of sec. The liquid metal is entering into the
cavity at a temperature of

Flow Simulation |
Temperature

Flow Image 10%

Flow Image 20%

Fill rate - 10%

Fill rate - 20%

Flow Image 30%

Flow Image 40%

Fill rate - 30%

Fill rate - 40%

Flow Simulation |
Temperature

Flow Image 50%

Flow Image 60%

Fill rate - 50%

Fill rate - 60%

Flow Image 70%

Flow Image 80%

Fill rate - 70%

Fill rate - 80%

Flow Simulation |
Temperature

Flow Image 100%

End of the
flow
The above
Fig. shows that the molten metal is filled % at sec, also it illustrates the variation in
the temperature in the cast. The colour contour ranges and labels are mentioned in the right side.

Flow Simulation | Velocity

Flow _Velocity Image

5%

Beginning of the
The aboveflow
Fig. Illustrates the velocity variations in the molten metal flow. From the aboce conout
ranges we shall able check the type of flow and the effects of velocity shall be interepreted.

Flow Simulation | Velocity

Flow _Velocity Image

10%

Flow Velocity Image

20%

Fill rate - 10%

Fill rate - 20%

Flow velocity Image

30%

Flow Velocity Image

40%

Fill rate - 30%

Fill rate - 40%

Flow Simulation | Velocity

Flow _Velocity Image

50%

Flow Velocity Image

60%

Fill rate - 50%

Fill rate - 60%

Flow velocity Image

70%

Flow Velocity Image

80%

Fill rate - 70%

Fill rate - 80%

Flow Simulation | Velocity

Flow _Velocity Image

100%

End of the
flow The above Fig. Shows the velocity contours of the metal after the end
of the flow.

Solidification Simulation |
Temperature

Solidification 2%

Beginning of
solidification
Solidification
temperature

pattern shows rate of solidification and time taken to solidify, it shows

beginning of solidification at the rate of

% and solidification begins at a temperature of C

and the

Solidification Simulation |
Temperature

Solidification image
10%

Solid rate - 10%

Solidification image
30%

Solid rate - 30%

Solidification image
20%

Solid rate - 20%

Solidification image
40%

Solid rate - 40%

Solidification Simulation |
Temperature

Solidification image
50%

Solid rate - 50%

Solidification image
70%

Solid rate - 70%

Solidification image
60%

Solid rate - 60%

Solidification image
80%

Solid rate - 80%

Solidification Simulation |
Temperature

Sectional view of Solidification

100%
Mark the hot zone

Sectional view: It shows solidification rate of 100% and time taken to solidify is sec. The risers
are still in hot condition (Please refer the temperature plots) to know the temperature of risers. This
method is achieving directional solidification.

Solidification Simulation | Niyama

Highlight the area of porosities

Highlights the area of probable porosity. White colour indicates free from micro
shrinkage, Yellow and Red are acceptable level and Blue is Major micro shrinkage area.
Controlling the process condition is important

Observations and comments

Write your observations on the casting and comments