Main Article Content
Abstract
The demands on the productivity and robustness of metal casting processes for high quality components are continuously increasing. Moreover, the financial considerations necessitate meticulous and reliable planning of the entire casting process before it is actually put into practice. A holistic approach to perform cradle to grave analysis of cast products is simulation-based metal casting. This method allows engineers to model, verify, and validate the process followed by its optimization and performance prediction in virtual reality. This paper provides insights on state of the art in simulation-based metal casting with reference to some case studies. Casting simulations software, mathematical models and solution methods, and casting process simulation together with the results obtained are clearly explained. The current practices revealed extensive utilization of simulation packages for defect minimization, yield maximization, and improved quality. The ongoing research on integration of casting simulations with mechanical performance simulations makes it possible to analyze the serviceability of cast parts. The reliability of cast part in service with dynamic loading of varying thermal and mechanical load cycles can be predicted through this integration. However, more rigorous work is needed in this area, particularly by developing the reliability prediction modules embedded in advanced simulation tools.
Keywords
Article Details
References
- AFS (2015), 49th Census of World Casting Production Modest growth in worldwide casting market.
- AFS (2016), Modern Casting census of world casting production – steady growth in global output.
- Amin LD, Patel S, Mishra P, Joshi D (2014), Rapid development of industrial castings using computer simulation. Indian Foundry Journal 60(8).
- Behera R, Das S, Dutta A, Chatterjee D, Sutradhar G (2010), Comparative evaluation of usability of FEM- and VEM-based casting simulation software. In 58th Indian Foundry Congress, Ahmedabad, India
- Bordas SPA, Conley JG, Moran B, Gray J, Nichols E (2006), A simulation-based design paradigm for complex cast components. Engineering with Computers 23(1): 25–37.
- Choudhari CM, Narkhede BE, Mahajan SK (2014), Methoding and simulation of LM 6 sand casting for defect minimization with its experimental validation. Procedia Engineering 97: 1145–1154.
- Dørum C, Hopperstad OS, Lademo OG, Langseth M (2007), Numerical modelling of the structural behaviour of thin-walled cast magnesium components using a through-process approach. Materials & Design 28(10): 2619–2631.
- Egner-Walter A, Kothen M (2013), Using stress simulation to tackle distortion and cracking in castings. Metallurgical Science and Tecnology 24(2).
- Fu MW, Yong MS (2009), Simulation-enabled casting product defect prediction in die casting process. International Journal of Production Research 47(18): 5203–5216.
- Hahn I, Sturm JC (2010), Autonomous optimization of casting processes and designs. In World Foundry Congress, Hangzhou, China October, 16–20.
- Hardin RA, Beckermann C (2012), Integrated design of castings: effect of porosity on mechanical performance. IOP Conference Series: Materials Science and Engineering 33(1): 012069.
- Hartmann G (2013), Material combinations in light weight casting components. Casting Plant and Technology 4: 32–37.
- Hu BH, Tong KK, Niu XP, Pinwill I (2000), Design and optimization of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation. Journal of Materials Processing Technology 105(1–2): 128–133.
- Jolly M (2002), Casting simulation: How well do reality and virtual casting match? State of the art review. International Journal of Cast Metals Research 14(5): 303–314.
- Jolly M (2003), Castings. In Comprehensive Structural Integrity 377–466. Elsevier
- Kermanpur A, Mahmoudi S, Hajipour A (2008), Numerical simulation of metal flow and solidification in the multi-cavity casting moulds of automotive components. Journal of Materials Processing Technology 206(1–3): 62–68.
- Liu XJ, Bhavnani SH, Overfelt RA (2007), Simulation of EPS foam decomposition in the lost foam casting process. Journal of Materials Processing Technology 182(1–3): 333–342.
- Mi G, Liu X, Wang K, Fu H (2009), Application of numerical simulation technique to casting process of valve block. Journal of Iron and Steel Research, International 16(4): 12–17.
- Nimbulkar SL, Dalu RS (2016), Design optimization of gating and feeding system through simulation technique for sand casting of wear plate. Perspectives in Science 8: 39–42.
- Olofsson J, Svensson IL, (2012), Incorporating predicted local mechanical behavior of cast components into finite element simulations. Materials and Design 34: 494–500.
- Rappaz M, Rettenmayr M (1998), Simulation of solidification. Current Opinion in Solid State and Materials Science 3(3): 275–282.
- Ravi B (2005), Metal casting: computer-aided design and analysis. New Delhi: Prentice-Hall of India.
- Ravi B (2008), Casting simulation and optimization: Benefits, Bottlenecks, and Best Practices. Indian Foundry Journal January (Special Issue).
- Ravi B (2010), Casting simulation – best practices. In Transactions of 58th IFC, Ahmedabad, India
- SiH M, Cho C, Kwahk SY (2003), A hybrid method for casting process simulation by combining FDM and FEM with an efficient data conversion algorithm. Journal of Materials Processing Technology 133(3): 311–321.
- Sikorski S, Dieckhues GW, Sturm JC (2012), Systematic optimization of aluminum sand casting gating systems. American Foundry Society.
- Sturm C, Seefeldt R (2007), Two for one–transferring proven filling characteristics from a single to a two cavity die casting die. Casting Plant & Technology 3: 44–52.
- Sun Z, Hu H, Chen X, Wang Q, Yang W (2008), Gating system design for a magnesium alloy casting. Journal of Materials Science and Technology 24(1): 93–95.
- Sutaria M, Ravi B (2014), Computation of casting solidification feed-paths using gradient vector method with various boundary conditions. The International Journal of Advanced Manufacturing Technology 75(1–4): 209–223.
References
AFS (2015), 49th Census of World Casting Production Modest growth in worldwide casting market.
AFS (2016), Modern Casting census of world casting production – steady growth in global output.
Amin LD, Patel S, Mishra P, Joshi D (2014), Rapid development of industrial castings using computer simulation. Indian Foundry Journal 60(8).
Behera R, Das S, Dutta A, Chatterjee D, Sutradhar G (2010), Comparative evaluation of usability of FEM- and VEM-based casting simulation software. In 58th Indian Foundry Congress, Ahmedabad, India
Bordas SPA, Conley JG, Moran B, Gray J, Nichols E (2006), A simulation-based design paradigm for complex cast components. Engineering with Computers 23(1): 25–37.
Choudhari CM, Narkhede BE, Mahajan SK (2014), Methoding and simulation of LM 6 sand casting for defect minimization with its experimental validation. Procedia Engineering 97: 1145–1154.
Dørum C, Hopperstad OS, Lademo OG, Langseth M (2007), Numerical modelling of the structural behaviour of thin-walled cast magnesium components using a through-process approach. Materials & Design 28(10): 2619–2631.
Egner-Walter A, Kothen M (2013), Using stress simulation to tackle distortion and cracking in castings. Metallurgical Science and Tecnology 24(2).
Fu MW, Yong MS (2009), Simulation-enabled casting product defect prediction in die casting process. International Journal of Production Research 47(18): 5203–5216.
Hahn I, Sturm JC (2010), Autonomous optimization of casting processes and designs. In World Foundry Congress, Hangzhou, China October, 16–20.
Hardin RA, Beckermann C (2012), Integrated design of castings: effect of porosity on mechanical performance. IOP Conference Series: Materials Science and Engineering 33(1): 012069.
Hartmann G (2013), Material combinations in light weight casting components. Casting Plant and Technology 4: 32–37.
Hu BH, Tong KK, Niu XP, Pinwill I (2000), Design and optimization of runner and gating systems for the die casting of thin-walled magnesium telecommunication parts through numerical simulation. Journal of Materials Processing Technology 105(1–2): 128–133.
Jolly M (2002), Casting simulation: How well do reality and virtual casting match? State of the art review. International Journal of Cast Metals Research 14(5): 303–314.
Jolly M (2003), Castings. In Comprehensive Structural Integrity 377–466. Elsevier
Kermanpur A, Mahmoudi S, Hajipour A (2008), Numerical simulation of metal flow and solidification in the multi-cavity casting moulds of automotive components. Journal of Materials Processing Technology 206(1–3): 62–68.
Liu XJ, Bhavnani SH, Overfelt RA (2007), Simulation of EPS foam decomposition in the lost foam casting process. Journal of Materials Processing Technology 182(1–3): 333–342.
Mi G, Liu X, Wang K, Fu H (2009), Application of numerical simulation technique to casting process of valve block. Journal of Iron and Steel Research, International 16(4): 12–17.
Nimbulkar SL, Dalu RS (2016), Design optimization of gating and feeding system through simulation technique for sand casting of wear plate. Perspectives in Science 8: 39–42.
Olofsson J, Svensson IL, (2012), Incorporating predicted local mechanical behavior of cast components into finite element simulations. Materials and Design 34: 494–500.
Rappaz M, Rettenmayr M (1998), Simulation of solidification. Current Opinion in Solid State and Materials Science 3(3): 275–282.
Ravi B (2005), Metal casting: computer-aided design and analysis. New Delhi: Prentice-Hall of India.
Ravi B (2008), Casting simulation and optimization: Benefits, Bottlenecks, and Best Practices. Indian Foundry Journal January (Special Issue).
Ravi B (2010), Casting simulation – best practices. In Transactions of 58th IFC, Ahmedabad, India
SiH M, Cho C, Kwahk SY (2003), A hybrid method for casting process simulation by combining FDM and FEM with an efficient data conversion algorithm. Journal of Materials Processing Technology 133(3): 311–321.
Sikorski S, Dieckhues GW, Sturm JC (2012), Systematic optimization of aluminum sand casting gating systems. American Foundry Society.
Sturm C, Seefeldt R (2007), Two for one–transferring proven filling characteristics from a single to a two cavity die casting die. Casting Plant & Technology 3: 44–52.
Sun Z, Hu H, Chen X, Wang Q, Yang W (2008), Gating system design for a magnesium alloy casting. Journal of Materials Science and Technology 24(1): 93–95.
Sutaria M, Ravi B (2014), Computation of casting solidification feed-paths using gradient vector method with various boundary conditions. The International Journal of Advanced Manufacturing Technology 75(1–4): 209–223.