Numerical Simulation of Mold Filling and Temperature Field on Shell-Mold Chilled Casting Process

The mold filling and temperature field simulations on shell-mold chilled casting process were studied during the trial-produce of car camshaft by commercial InteCAST software. For the sake of process optimization, two casting processes namely original process and optimized process were used to compare. The result showed that casting defects such as gas cavity and inclusion were prone to form in camshaft casting for original process during mold filling process, at the same time for original process the reason why the more defects such as misrun, cold-shut and material property in camshaft casting are clarified by coupling simulation of fluid field and temperature field. Based on the simulation result, during mass-produce of car camshaft application on optimized process the casting defects have been significantly prevented and great economic benefits and social benefits are brought for both foundry industry and society.