**1. Introduction**

Simulation imitates a real phenomenon by the use of certain mathematical equations. Metal casting is a manufacturing process where molten metal is poured into a mould cavity of required shape and size and allowed to solidify. Naturally, metal casting simulation is a very complex phenomenon which involves flow of fluid, heat transfer between mould and molten metal etc. It is often said that the development of accurate simulation software is a 'rocket science for rocket scientists'. Actually, metal casting is a process which has numerous associated controlling factors. Therefore, the key to develop a practical useful casting simulation software is to figure out the related most important parameters. Several researchers have worked hard for several decades to find out the same. Geometry, material, and process are three major influencing factors related to metal casting [1].

The casting simulation software producing farms always keep target to accurately simulate the physical phenomena as far as possible like the mould filling, associated heat-transfer, solidification pattern of the metal/alloy, and the involved

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*Casting Processes and Modelling of Metallic Materials*

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Optimal Feeding Design of Castings,

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[1] John Campbell: Castings,

**References**

phase transformation of castings [2]. It is ubiquitous that a set of governing equations are required to model these phenomenon in a computer program. Now a days, these modeling methodologies are so strong that they can accurately predict the microstructure and mechanical properties of the castings. It can also pin point the position of internal defects like shrinkage porosity, sand inclusions and cold shuts etc. The simulation software can be used for the development of any new castings or it can be used for standardize any existing casting for any design change to improve yield of the casting without shop floor trial. For these reasons, casting simulation has become an indispensable tool in modern foundries. No foundry can produce high-quality castings particularly integrated castings without simulation for the first time. The present dynamic market demands fast response to customer needs at the right cost and also within stipulated time.

Some popular casting simulation softwares which are available to foundry engineers are AutoCAST, MAGMASoft, ProCAST, SOLIDCast, CAP/WRAFTS, CastCAE, Castflow, Castherm, JSCast, MAVIS, Nova-Solid/Flow, PAM-CAST, RAPID/CAST, and SIMTEC etc. These simulation software generally follow any one the following numerical technique to solve the related differential equations, Finite Differences Method (FDM), Finite Volumes Method (FVM), Finite Element Method (FEM) and Vector Element Method (VEM) etc. ProCAST, SOLID Cast, OPTI Cast and FLOW Cast are based on the FEM technique while QuikCAST is based on FDM technique and AutoCAST is based on VEM technique.

It is easily understandable that the simulation software will perform well if and only if the input parametrs are close to the real world values. Most critical input values for such simulation software are the thermo-physical properties of cast metal and mold, as well as interface boundary conditions. But these values are temperature dependent. Therefore, the values are difficult to acquire for different metal-mold-process combinations. As a result, the outcome of simulation software may deviate from reality.

In this chapter, advantages of casting simulation software, limitations, and some best practices are illustrated. In addition, some live examples have been cited to understand the process logically and scientifically.
