Numerical modeling of casting processes

Recent progress on work related to numerical modeling of casting processes at the Industrial Materials Institute (IMI) is presented. Depending on the type of casting process involved, two different modeling approaches are used. The first, applied to simulate laminar or turbulent flow in the cavity of thin wall castings, is based on a 2D shell element model. This has the advantage of being computationally efficient from the CPU standpoint while, at the same time, provides a reasonably accurate solution to the problem. In the second approach, a 3D finite element method is used for parts that are thick (such as in low pressure or gravity casting), or where the problem is associated with both the part and mold (such as in heat transfer calculations). Whatever the technique chosen, in performing numerical modeling, the foundry hopes to use the results to optimize die and part design, as well as to reduce manufacturing costs. By being able to predict filing, solidification stresses and shrinkage, a good idea of product quality and performance can often be obtained at the initial stage of the product development cycle. Examples of simulations conducted using an experimental die, an automotive housing and a wheel in an aluminum alloy are given.