RNariman MetalCasting Consulting Inc Casting Engineering with Simulation

RNariman Metal-Casting Consulting, Inc. Casting Engineering with Simulation Work Casting Planning in the Virtual Environment Process Steps and Deliverables - Example Rafael Nariman RNariman Metal-Casting Consulting, Inc. 7121 34 th St. E. Sarasota, FL 34243 Phone: 941 893 5202 Mobil: 570 786 9142 Email: rafael. nariman@gmail. com

RNariman Metal-Casting Consulting, Inc. Inputs Ø Imported CAD model of part. Ø Often sent by Client via Email Ø Limited part modeling from drawings also available. Ø Alloy Composition Ø Steel Casting Example Ø Alloy – CF 8 M

RNariman Metal-Casting Consulting, Inc. Examples of additional information that may be required Ø Melt and ladle capacities Ø Mold and core sands Ø Molding method Ø Pouring method Ø Pattern and Core Box details Ø NDE requirements

RNariman Metal-Casting Consulting, Inc. Model editing: Ø Ø Model prep. for casting simulation Addition of finish stock Global shrinkage application In this case, hub design modification

RNariman Metal-Casting Consulting, Inc. Model Editing: Ø Addition of vane fillets

RNariman Metal-Casting Consulting, Inc. Model editing: Ø Addition of sink risers. Ø (Necessary to prevent virtual loss of mass during the riser-less simulation)

RNariman Metal-Casting Consulting, Inc. Riser-less solidification simulation: Ø Mold setup for the riser-less solidification simulation. Ø In this step we determine the location and configuration of hotspots and feeding zones.

RNariman Metal-Casting Consulting, Inc. Riser-less solidification simulation: Ø Solid Fraction Evolution – 70% solid. Ø Mass over 70% solidified becomes invisible. 100 s Solidification at two different times pointing to three feeding zones in this part. 150 s

RNariman Metal-Casting Consulting, Inc. Riser-less solidification simulation: The 70% solid fraction fringe plot after 195 seconds confirms the presence of three feeding zones. 170 s 195 s

RNariman Metal-Casting Consulting, Inc. Riser-less solidification simulation: The shrinkage porosity plot below confirms the presence and location of the three feeding zones. 560 s The hub zone is last to solidify

RNariman Metal-Casting Consulting, Inc. Riser-less solidification simulation: Ø Thermal Modulus plot provides numerical data for the design and dimensioning of feeding systems. Ø Information on a Risering Methodology using the Pro. Cast Modulus Plot available upon request.

RNariman Metal-Casting Consulting, Inc. Intermediate Risered Part - Solidification Simulation: Ø Ø Used to fine-tune the feeding system No modeled feeding aids and chills used at this stage Sand risers and film chills used to expedite the process. Several simulation iterations often required.

RNariman Metal-Casting Consulting, Inc. Intermediate Risered Part - Solidification Simulation: The Solid Fraction plot demonstrates that the part is correctly fed by the risers, except for a secondary indication in the hub riser neck.

RNariman Metal-Casting Consulting, Inc. Intermediate Risered Part - Solidification Simulation: This iteration has the intended feeding aids on the top side. There is no secondary indication in the hub area.

RNariman Metal-Casting Consulting, Inc. Intermediate Risered Part - Solidification Simulation: Ø The shrinkage porosity plot shows al major indications in riser locations. Ø We can proceed to the Flow simulation stage.

RNariman Metal-Casting Consulting, Inc. Gating and Flow Simulation Base-Line Considerations: Ø Ø Ø Gating system designs must conform to the pouring process. Systems for bottom and top pouring are different. Gating System design depends on alloy type. For top pouring, chocked systems are mostly used. For bottom pouring, open systems are mostly used. In-gate velocity is a basis for system dimensioning. Filter systems are useful with certain alloys. Riser/Filter systems can be effective in some cases. Foundry experience with filtration is key to its success. Bottom Gating is effective for casting cleanliness. Bottom Gating is not always practical. The pouring operation is a major variable that can’t be simulated.

RNariman Metal-Casting Consulting, Inc. Gating and Flow Simulation Evaluation of two Gating Systems System A: System B: Ø Ø Ø Ø Ø Choke at sprue bottom Flow rate: 13 lb/s Two in-gates into side risers In-gates at near bottom of part Two filters Choke at sprue bottom Flow rate 13 lb/s Four in-gates into side risers Parting line runners

RNariman Metal-Casting Consulting, Inc. Gating and Flow Simulation B A Fluid Velocity Plot: Vector plot demonstrates more momentum at in-gate locations in System A

RNariman Metal-Casting Consulting, Inc. Gating and Flow Simulation Section plane A B Ø In-gate velocity is greater with system A, but it is under a critical value of. 5 m/s. Ø System A is chosen on account of the added benefits of filtration and bottom entrance.

RNariman Metal-Casting Consulting, Inc. Final setup CAD views Final Simulation

RNariman Metal-Casting Consulting, Inc. Final Simulation mold setup

RNariman Metal-Casting Consulting, Inc. Final Simulation 6 s Ø Mold fill/temp. simulation. Ø No problems observed. 10 s

RNariman Metal-Casting Consulting, Inc. Final Simulation 18 s Ø Mold fill/temp. simulation. Ø No problems observed. 23 s

RNariman Metal-Casting Consulting, Inc. Final Simulation Surface Temperature Plot during Solidification: Ø Ø Ø This plot gives broad information on the progress of solidification It is not useful to validate riser and gating schemes. This plot is useful in the analysis of Hot Tearing and Cracking issues Cracking and tearing in castings are surface phenomena. Temperature differences are a prime cause for these problems. Actual examples are available

RNariman Metal-Casting Consulting, Inc. Final Simulation Mold fill and solidification simulation (70% solid fraction fringe plot)

RNariman Metal-Casting Consulting, Inc. Final Simulation 222 s Ø Solidification Ø No unfed pools observed 350 s

RNariman Metal-Casting Consulting, Inc. Final Simulation 600 s Ø Solidification Ø No unfed pools observed 1330 s

RNariman Metal-Casting Consulting, Inc. Final Simulation Ø Shrinkage porosity plot Ø All major indications are in risers and gating system

RNariman Metal-Casting Consulting, Inc. Ø Ø Ø Final Simulation Niyama Criterion Plot Identifies centerline indications in plate sections Potential fine porosity inside vanes This is typical with vane designs This is acceptable Industry-wide

RNariman Metal-Casting Consulting, Inc. Deliverables Ø Movies and Images of all simulation work Flow and Surface Temperature (download videos on webpage) Flow and Solidification

RNariman Metal-Casting Consulting, Inc. Deliverables Ø CAD models of rigged parts Ø CAD models of mold components as needed.

RNariman Metal-Casting Consulting, Inc. Deliverables Ø Dimension drawings of risering and gating components as needed

RNariman Metal-Casting Consulting, Inc. Deliverables Ø Pattern construction information as required

RNariman Metal-Casting Consulting, Inc. Deliverables Ø Required part production information. Mold box dimensions

RNariman Metal-Casting Consulting, Inc. Deliverables Ø CAD models of mold components Ø For use with the 3 D print process

RNariman Metal-Casting Consulting, Inc. Support: Ø The objective is not fancy engineering Ø The objective is good casting production from the first part cast Ø Our track record in achieving that goal is very good Sub-standard results? Ø Ø We find the root causes Regardless of who is responsible…. We do what’s necessary to tweak or correct… At no additional cost

RNariman Metal-Casting Consulting, Inc. Please contact me with questions about this report. Rafael Nariman RNariman Metal-Casting Consulting, Inc. 7121 34 th St. E. Sarasota, FL 34243 Phone: 941 893 5202 Mobil: 570 786 9142 Email: rafael. nariman@gmail. com