**2. Application of casting simulation software**

Casting troubleshooting, method optimization and part design improvement are the main three applications of casting simulation software. Therefore, these are described here in brief.

#### **2.1 Casting Troubleshooting**

As the title suggests, trouble in existing casting like high or varying level of internal defects (shrinkage porosity, sand inclusions, cold shuts, etc.), or poor yield of castings can be eliminated by using the simulation software. To address such problems, casting engineers' first use to calibrate the software by making the exact platform in the virtual world. Now the simulation defect and real world defects are compared for calibration. Once achieved, the engineer can change the inadequate size or location of feeder or gate. It is also a fact that the simulation software reveals the defect positions where otherwise in general engineer don't look for. Regarding the improvement of yield, the foundry engineer can play with the simulation software in a hope to reduce the oversized feeders or risers (if any). If no defect is observed in simulation software by reducing the feeder dimensions then the engineer can go for shop floor trial. If the result agrees then definitely, the yield will improve.

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**3.1 Inputs**

software.

*Simulation and Validation of Castings in Shop Floor DOI: http://dx.doi.org/10.5772/intechopen.94596*

money both in foundry and machine shop.

obtained from OEM customer.

**3. Operational Methodology of simulation software**

provided on the CAD model if not given earlier.

This section has been discussed in following three subsections.

Method based [4]. So this discussion is applicable for FEM based simulation

**2.3 Part design improvement**

In methoding of castings, solidification simulation executes an essential role in acquiring the best possible quality of castings. Simulation software is beneficial for both under development as well as existing castings, and reduces number of shop-floor trials. The methodings for example, casting orientation, mould layout, feeders, feed-aids, and gating etc. are altered on a computer, and pretended to review for defects, if any. Numerous iterations are performed until the coveted quality and yield are obtained. It is noteworthy to mention that even trivial, insignificant advancements in existing castings that are being manufactured in huge numbers, can direct to notable enhancements in the utilization of matter, energy, machinery and labour resources. Likewise, simulation is decisive for large, heavy castings under development since the cost of trials or repair is limited. Several programs have been included in the algorithms for automated (user-guided) optimization of feeders and gating channels [3]. Many researchers have proclaimed that approximately 90% of the defects in parts are due to errors in design and hardly 10% are due to production difficulties. The casting simulation software can also be used for calculating the cost of the job in an indirect manner. In the very initial step of design of a to be cast part should be simulated, otherwise it may so happen that the proposed part is not at all castable. A thumb rule says that the cost to change in design increases ten times in every step of the design and manufacturing process. Therefore, method optimization should be done using the casting simulation software as early as possible in a designing process and this practice can save a lot of

Thick junction and long thin section in a casting may result in shrinkage porosity and cold shut. Therefore, if a part designer encounters such situations then he should immediately consult the foundry engineer to check the castability of the part using casting simulation software. Early detection of castability may also insist the part designer to do minor change without affecting the functionality of the part.

Maximum commercially available casting simulation software are Finite Element

• 3D CAD model is the main input for any casting simulation software. The CAD model can be created using a solid modeling program. Model of the part can be

• Various allowances like draft, machining, shrinkage, distortion etc. are to be

• Now, the model has to mesh. Meshing means that the model is to be split into several simple elements. A tinier mesh size returns more delayed but more

**2.2 Method optimization**
