Real-time correction model-based simulation for prediction of shrinkage porosity in investment casting

Numerical simulation of heat transfer is an effective tool in the manufacture of high-quality castings. However, the discrepancy between simulation and the actual process is always inevitable due to the simplification of boundary conditions, which reduces the accuracy of defect prediction. In this study, a simplified mathematical model of heat transfer is developed to simulate the shell temperature evolution during the shell transfer process in investment casting. On this basis, a real-time dynamic correction method is introduced, leveraging thermocouple measurements to adjust for changes in ambient temperature, material emissivity, and thermal properties, ensuring accurate simulation. By incorporating these dynamic factors into the mathematical model with real-time corrections, this model aligns closely with experimental results and offers process parameter references for subsequent casting simulations. The dynamic temperature adjustments enhance shrinkage porosity predictions, aiding in the quality assurance of investment casting.