**4. Intelligent design assistant**

As stated earlier, Simulation software furnishes reliable and precise outcomes if the CAD model, FEM mesh, material characteristics and boundary conditions are exact (otherwise: garbage in, garbage out). Material characteristic and boundary conditions data usually have to be ascertained and fine-tuned by experimentation. This exercise may take numerous weeks, which is beyond the scope of average organizations. Simulation programs demand engineers with higher educational qualifications, CAD/CAM experiences and casting design knowledge to conduct the simulation and interpret the outcomes correctly. The programs are computationintensive and need robust engineering workstations. Even then, any particular iteration of CAD model making, mesh creation, boundary condition stipulation, simulation and visualization can consume 2–5 days for an intricate component. Thus it may demand many days to reach an optimal casting scheme.

**57**

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

into the simulation software.

model is built automatically.

built.

in-between.

part model.

To address these issues now a days, some simulation software provides a single integrated environment for casting design, modeling, simulation, analysis and project data management. Advanced geometric reasoning and knowledge-based functions have been incorporated in the software, making it work like an intelligent assistant to casting engineers [5]. The methodology for casting design (mainly feeding and gating systems), process simulation, castability analysis and optimization is

• The CAD model of the part is exported in standard. STL format and imported

• The program automatically produces the mesh, fixes the boundary conditions, measures the advancement of solidification, post-processes the results and demonstrates the position and degree of shrinkage porosity. All the events, as

• Now if any porosity is observed in the simulation results then a chill is modeled automatically in that zone to increase the heat transfer rate. Modified simula-

• Likewise, the simulation software automatically calculates modulus (ratio of volume of the casting to the surface area of the casting) in the hot spot zone of the casting and properly designs the feeder dimensions in such a way that its solidification time is more than the hot spot. After user approval, the feeder

• Additionally, the gating plan is designed by this program semi-automatically. The user exclusively defines the ingate joining points on the part surface. The program automatically proposes the sprue location and the runner path, which can be altered by the user if needed. Then the dimensions of all gating parts are automatically calculated, and a solid model of the gating system is

• The solid models of the feeder, chill and gating system, are represented for visual feedback. The size of feeder and chill are optimized through several iterations of design-model-simulate-analyze until simulation prognosticates

• Finally, casting is designed on a scale of 0-100. A value of zero implies impossible to cast and 100 indicates ideal castability. The actual values usually lie

The Z-CAST is Finite Difference Method (FDM) based simulation software. To

zero porosity defects even for the highest quality requirements.

**5. Example: workflow of a casting simulation software (Z-CAST)**

create a new project following steps are to be followed.

• The program automatically recommends the mould size and subsequently upon the approval from the user, generates the mould model encompassing the

• Now, an initial casting solidification simulation was performed.

tion reveals that there is reduction in porosity.

mentioned above, take less than 15 minutes on a Pentium computer.

performed by intelligent simulation software is explained below.

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

*Casting Processes and Modelling of Metallic Materials*

**3.2 Outputs**

**3.3 Analysis**

**4. Intelligent design assistant**

temperature.

• Next, the boundary conditions have to be defined.

stable outcomes. Adaptive meshing (finer in decisive domains and coarse elsewhere) provides quicker outcomes without compromising on the precision.

• Following meshing, material characteristics like density, thermal conductivity, specific heat, latent heat etc. are to be provided as input to the software.

• Simulation software furnishes reliable and precise outcomes if the CAD model, FEM mesh, material characteristics and boundary conditions are exact.

• The principal outputs of simulation applications incorporate animated visualization of mould filling, casting solidification, and further cooling to room

• Mould filling simulation assists in forecasting the total filling time as well as help in predicting following casting defects like mould erosion (heading to sand inclusions), incomplete filling (cold shuts and misruns), and air entrapment. Blowholes, produced by entrapment of gases, are yet difficult to predict.

• The outcomes of solidification simulation incorporate colour-coded freezing profiles with respect to time. These temperatures profiles help in predicting the

• The casting simulation software can also predict the microstructure,

Casting simulation software can only help foundry engineers to analyze the effect of a particular method design on the yield and quality. The software enables us to 'look through' the virtual mould. However, it can not perform better by itself. The outcomes should be analyzed by a knowledgeable foundry engineer. Application of casting simulation software can improve the productivity of a company and also it is a tool for the foundrymen to succeed but it cannot substitute him.

As stated earlier, Simulation software furnishes reliable and precise outcomes if the CAD model, FEM mesh, material characteristics and boundary conditions are exact (otherwise: garbage in, garbage out). Material characteristic and boundary conditions data usually have to be ascertained and fine-tuned by experimentation. This exercise may take numerous weeks, which is beyond the scope of average organizations. Simulation programs demand engineers with higher educational qualifications, CAD/CAM experiences and casting design knowledge to conduct the simulation and interpret the outcomes correctly. The programs are computationintensive and need robust engineering workstations. Even then, any particular iteration of CAD model making, mesh creation, boundary condition stipulation, simulation and visualization can consume 2–5 days for an intricate component.

Thus it may demand many days to reach an optimal casting scheme.

position of shrinkage porosity based on Niyama criteria.

mechanical properties, residual stresses etc.

**56**

To address these issues now a days, some simulation software provides a single integrated environment for casting design, modeling, simulation, analysis and project data management. Advanced geometric reasoning and knowledge-based functions have been incorporated in the software, making it work like an intelligent assistant to casting engineers [5]. The methodology for casting design (mainly feeding and gating systems), process simulation, castability analysis and optimization is performed by intelligent simulation software is explained below.

