The Conditions for Application of Foundry Simulation Codes to Predict Casting Quality

The Conditions for Application of Foundry Simulation Codes to Predict Casting Quality


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Abstract. Casting processes are widely used to produce metal components wherein the cast iron castings represent more than 70% of the world production of castings. Designing a new casting technology requires incurring large costs associated with the preparation of instrumentation necessary to perform casting moulds. Therefore, the simulation codes currently applied in the foundry industry are used primarily to optimize the casting quality, quality mainly connected with the defects location such as shrinkage porosity. In this case, it is very important for the simulation code user to master the phase of pre-processing, which is the best possible, corresponding to the actual casting-mould system, formulation of the model which along with the relevant differential equations also includes defined certain conditions (geometric conditions, the physical parameters of casting-mould, initial and boundary conditions). The lack of as complete as possible identification of these values, used in modeling dependencies, is the cause of limitation of the development and scope of models describing casting solidification – which sometimes translates into a foundry’s negative attitude to the usefulness of the simulation codes, because of incorrect predictions on casting quality. Correct model installation and the use of a database corresponding to the model are the development condition of the simulation code in the foundry practice. The paper describes the utilitarian aspects connected with these problems.

Casting, Simulation Codes, Casting Defects, Validation, Thermal Properties

Published online , 8 pages
Copyright © 2020 by the author(s)
Published under license by Materials Research Forum LLC., Millersville PA, USA

Citation: POPIELARSKI Paweł, The Conditions for Application of Foundry Simulation Codes to Predict Casting Quality, Materials Research Proceedings, Vol. 17, pp 23-30, 2020


The article was published as article 4 of the book Terotechnology XI

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