Defect Free Casting by Using Simulation Software

Abstract

The use of Aluminum castings parts in the automotive industry has increased dramatically over the past few decades. The driving force for this increased use is vehicle weight reduction for improved performance. In many cases the mechanical properties of the cast aluminum parts are superior to those of the cast iron or wrought steel parts being used.This paper proposes the computer simulation of the sand casting of Aluminum Plate. It aims to study the behavior of fluid flow during mould filling and solidification and to optimize the process parameters, which help to predict and control casting defects such as gas porosity and shrinkage porosity. Here an attempt is being made to model and simulate the casting process using the AutoCAST software. The technological as well as practical aspects of using casting software are illustrated with an industrial case study.