Computer-aided simulation of casting processes (mold filing and solidification processes) which has become an increasingly standard tool.
Using this, problems which occur with regard to inflow behavior (turbulences), cooling and the possible tendency for cavities to form can be recognized before a casting is developed and can be remedied at a low cost. The ability to produce the casting with guaranteed quality can therefore be simulated parallel to the construction.
In addition to the simulation of mold filling, solidification and cooling, software programs which simulate thermoelastic/thermoplastic stresses and the cracking of castings are also available. Furthermore, the gate and feed technology and the mold design can be improved, therefore reducing the costs for reworking and waste considerably.
This integration of the simulation in the production of castings is supported by the fact that simulation programs today do not require any particular understanding of computers per se or of the formulation of mathematical and physical models. However, the user should bring a sound understanding of casting and the process flows with them to the foundry.
Today, in addition to “normal” simulation, a large range of different models are offered, for example for die casting, low pressure casting, for the lost foam process and for the DISAMATIC process and the rotacast process.
In order to create information from this enormous amount of data, the results can be visualized so that the calculated results can be understood and interpreted intuitively. To do this, the information is processed and compressed by the software. Castings are three-dimensional and these dimensions can be made tangible with “virtual reality" today.
Fig 1: Foseco Foundry Division Vesuvius GmbH, Solidification simulation