Metal casting simulation

This technology allows engineers to predict and visualize the flow of molten metal, crystallization patterns, and potential defects in the casting before the start of the actual production process.

By simulating the casting process, manufacturers can optimize mold design, reduce material consumption, and improve the quality of the final product.

The theoretical foundations of heat conduction, critically important for casting simulation, were established by Jean-Baptiste Joseph Fourier at the École polytechnique in Paris.

[5] The first use of digital computers to solve problems related to casting was carried out by Dr K. Fursund in 1962, who considered the penetration of steel into a sand mold.

[8] The 1980s marked a significant increase in research and development activities around the topic of casting process simulation with contributions from various international groups, including J. T. Berry and R. D. Pielke in the United States, E. Niyama in Japan, W. Kurz in Lausanne, and F. Durand in Grenoble.

[12][13] The production of casting is one of the most complex and multifaceted processes in metallurgy, requiring careful control and an understanding of a multitude of physical and chemical phenomena.

To effectively manage this process and ensure the high quality of the final products, it is essential to have a deep understanding of the interaction of the various casting parameters.

The main drawbacks are the need for a finite element generator, the complexity of the equations, and large requirements for memory and time resources.

[22] Despite higher computational resource requirements and complexity in implementation compared to the finite difference method and finite volume method, the FEM provides high accuracy in modeling boundaries, complex geometries, and temperature fields, which is critically important for predicting defects in castings and optimizing casting processes.

[27] The process begins with the delivery of the 3D model and drawing of the part to the foundry technologists, who coordinate the casting configuration with the mechanical workshop and determine the margins.

[citation needed][29] This cycle is repeated until suitable castings are obtained, after which the technology is considered developed and implemented in mass production.

[37] The simulation of the casting process reflects the user's knowledge, who decides whether the filling system has led to an acceptable result.