Abstract: For wide spread use of casting simulation in industry, the software programs have to be easy-touse, economical, reliable, and well-supported. This has been made possible by combining methoding, solid modelling (of risers and gating), simulation, and optimisation in program called AutoCAST. The solidification computation engine is based on a hybrid technique combining Vector Element Method and Finite Difference Method, enabling accurate prediction of shrinkage porosity for even complex castings in a few minutes. By incorporating algorithms for intelligent design of feeders and gating, and their automated solid modelling, the learning curve for the software has been reduced to a few hours. It has been used for live troubleshooting and optimisation of hundreds of castings in the presence of method engineers. The user-friendliness of the software also facilitates collaboration between foundry and OEM engineers to improve the casting design for ease of manufacture, leading to significant reduction in defects, costs, and lead-time. Two such cases of industrial steel castings are presented here, to illustrate the technology, methodology, and benefits involved.
Publication Year: 2007
Publication Date: 2007-01-01
Language: en
Type: article
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