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Computer simulation of casting processes

Компьютерное моделирование литейных процессов
Casting processes simulation system enable to analyze technological process of casting at the stage of development, pick gate feeding system and determine optimal technological parameters of casting process. Such simulations use in design through enables to save up on possible adjustment of pattern equipment and shorten period of casting technology development. Engineering of systems with complex geometrical configuration such as simulation of die filling and ingot freezing, is done with the help of approximation digital methods such as finite element method. The essence of the method is differential equations solution in certain fields split into a final number of sub-fields. Solution of such task is finding function value in element nodes. Finite element method allows to max take into account ingot geometry and detect minor defects. The Department of Casting Processes actively uses CAE pack of ProCast (ESI Group), on of acknowledged leaders in the market. Simulation result mainly depends on how adequate is the computer model to real conditions of ingot forming. That is why false design conditions lead to simulation mistakes. The biggest impact on simulation result has the accuracy of thermal and physical characteristics of metal and die. ProCast pack helps to get an idea of the following casting processes: 1. Metal filling of the die The flow is described with full Navier-Stokes equation and is done parallel with temperature and strain analysis. Problem solver includes and specialized model to analyze turbulent flows, which allows to get an idea of how the die is filled, on turbulent flow, logs, underfills and cold shuts. 2. Alloy crystallization and ingot freezing Simulation of temperature fields in the ingot and the die, thermal centres of the ingot, die overheat places, shrinkholes and macroporosity. 3. Formation of shrink and gas defects Upgraded porosity module enables to simulate interdendrite shrinkage given dissolved gases in the liquid alloy. Model used in the module is based on Darcy’s equation solution and micro segregation of gas, 4. Ingot strains and cracks and shrinkage formation forecast Strain simulation enables to forecast with high accuracy thermal and mechanical contacts, retained stress, deformations, hot cracks and strains in ingot and die.


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