CHAPTER 3.

METHODOLOGY

This chapter describes the background theory and different

methods of simulations, details on finite element analysis, different

types of simulation used in the sand castings, the research methods,

working flow and standard operation procedures of ProCAST were

interpreted. First, the capabililities of soft ware’s, types of simulation

used in sand castings, secondly the research flow of present work was

shown, and then a brief introduction of operation guide of ProCAST is

developed.

3.1. SOFTWARE PACKAGES CAPABILITIES

Most of commercially available simulation software packages,

that support solidification and mould filling analysis, are developed

based on either the Finite Element Method (FEM) or the Finite

Difference Method (FDM) [82].

3.1.1 Finite Element Method

The finite element method for analysing structural parts has

been since the 1950s. The method was primary developed for use in

the aerospace and nuclear power industries. Here, the safety of the

structures is critical: they involve large capital expenditure and the

economic consequences of a failure are very severe, so the cost of the

analysis is justified. Today the method is also extensively used in

areas such as the automotive industry, where components are

relatively cheap but are manufactured in large volumes. Furthermore,

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any small reduction in the safe weight of a component such as a

connecting rod can lead to additional benefits in areas such as

vibration reduction and fuel economy [83]. The growth in the usage of

finite element methods is due to the developments in computing

technology, in recent years. Today there are a number of large

software companies developing and marketing finite element and

associated modelling software. As a result, there exist commercial

finite element packages capable of solving the most sophisticated

problems, in a wide variety of areas [84].

In spite of the abundance and power of commercial software, it

is still very important to have an understanding of the principles of

the technique, so that an appropriate simulation can be selected,

correctly defined and interpreted.

The complete mathematical discussion is not important to the

sand casting engineer, it is important to realize the practical

differences. FDM uses an orthogonal mesh to represent cavity and

mould geometry. It is very hard to model a complex casting shape,

especially a thin wall casting, with a reasonable number of elements.

Even use of millions of elements may not improve the analysis result

too much because the interface length on any out-of-plane section is

still incorrect. This casting/mould interface is one of the most

influential variables in sand mould process. FEM can use not only a

non-orthogonal mesh, but also different types of mesh where needed.

In FEM, it is easy to fit in zero-thickness interface elements, which

model the cast metal/mould contact. Be-cause of this boundary

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element there is a chance to divide the casting and mould surface

temperatures. This is not the case with FDM. The geometric flexibility

of FEM is essential for sand casting engineers to obtain accurate

analysis results.

In addition, stress analysis of parts can be performed with FEM

with little or no modification of the mesh. Successful use of the same

FEM mesh for casting solidification analysis and stress analysis has

been reported. Thus, FEM is better suited to sand casting analysis

[86]. Popularly recognized casting simulation programs presently

available to foundry engineers are listed in Table:3.1

Table:3.1 Recognized casting simulation programs [75]

Software Program Company and Location

CastCAE CT-Castech Inc. Oy, Espoo,

Finland

Castflow, Castherm Walkington Engineering, Inc.,

Australia

PAM-CAST/ProCAST ESI Group, Paris, France

MAGMASoft MAGMA GmbH, Aachen,

Germany
JSCast Komatsu Soft Ltd., Osaka, Japan

SOLIDCast Finite Solutions, Inc., Illinois,

USA

AutoCAST Advanced Reasoning

Technologies P. Ltd., Mumbai

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3.1.2. Simulation software’s

SOLIDCast uses the Finite Difference Method (FDM) of heat

transfer calculation, combined with a unique tracking of volumetric

changes in the metal, to predict the temperature and volume changes

in a casting as it is poured, solidified and cooled. This combined

thermal-volumetric approach has proven to be an extremely accurate

method of predicting various casting problems, including micro- and

macro-porosity, hot spots and other defects [85].

MAGMASOFT was created by MAGMA, a German company

founded in 1988. This Finite Deference Method program may help the

user stay away from gating and feeding problems, forecast casting

quality, aids permanent mould design and reduce fettling costs. It

contains many modules for calculating specific processes, such as

high-pressure die casting, low-pressure die casting, lost foam, low-

pressure die casting for wheel castings, etc., optimization modules,

and modules that could predict thermo elastic/thermoplastic stresses,

residual stresses and strain in castings and moulds, modules that can

predict the solidification sequence of cast iron alloys using microscopic

kinetic growth models, heat treatment modules, etc.

3.2 ProCAST OVERVIEW

Recognized for years as the leading Finite Element solution for

casting process simulation, ProCAST 2004 offers new graphical user

interfaces and improved performances in speed, accuracy and

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modelling capabilities. Is a modular software solution offering an

extensive suite of modules and engineering tools to meet the most

challenging requirements of the casting industry. In order to address a

wide variety of casting processes and related issues, the software

capabilities include automatic mesh generation, thermal analysis

including radiation effects, flow analysis for mould filling, fully

coupled thermal, flow and stress analysis, and advanced metallurgical

options. It is leading finite element solution for Casting Process

Simulation. Based on proven Finite Element technology, it provides a

complete solution covering a wide range of casting processes and alloy

systems [86].

3.2.1 Introduction

Is a three dimensional solidification and fluid flow package

developed to perform numerical simulation of molten metal flow and

solidification phenomena in various casting processes, primarily die

casting (gravity, low pressure and high pressure die casting) and sand

casting. It is particularly helpful for foundry applications to visualize

and predict the casting results so as to provide guidelines for

improving product as well as mould design in order to achieve the

desired casting qualities. Prior to applying the simulation extensively

to create sand casting and die casting models for the simulation of

molten metal flow (mould filling) and solidification (crystallization in

the process of cooling).the cast and mould design of the experiment is

transformed into a 3D model and imported into ProCAST to conduct

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the sand casting process simulation. In the present work simulation of

mould filling solidification of casting of CO2 sand alloy steel castings

are carried out.

3.2.2 Research Flow

The purpose of this present work is to simulate the mechanism

of the solidification of alloy steel sand castings, and analyze the

results to give some aspects of logical thoughts for experiments

designation, and to optimize the casting parameters in order to

achieve better properties of steel castings. The procedures were mainly

divided into three stages. They were Simulation Preparation,

Computer Aided Simulation, and Analysis. Each stage contained

several steps. Researcher followed this operation flow to try and

examine different influencing factors, such as molten metal

temperature, mould material, inlet velocity, substrate pre heating

temperature, and radiation. In the first stage, observation of fluid flow

was most important because all the model construction, parameters

designation, and questions description are based on observing

substantial experiments. The purpose of this stage was to gather more

data for simulation experiments, and all the material properties,

mould properties, relationships between materials and surroundings

are needed. In addition, the second stage was the simulation, and this

stage was totally under computer operation, including model

construction, input factors setting, problem solving, result

obtainment. Finally, the final stage was to show the results of

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simulation, to build a data base and to analyze, then to find out

convincing conclusions that would improve the casting. Fig: 3.1(a)and

Fig:3.1(b) is the flow charts showing the entire procedures conducting

to this research.

Fig:3.1 (a) – Research Procedure[71]. Fig:3.1(b) – Steps needed to-

Make simulation[71].

3.2.3 Solid modelling of casting in ProENGINEER Wildfire-2.0

The solid model of a cast product is the backbone for various

software programs that help in improving the consistency and speed

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of different tasks in casting development. First step is to convert a

part drawing sheet shown in Fig:3.2 and 3.3 given by the customer in

to a CAD model, generally first we will make a 3D solid model using

CAD software and then make a orthographic 2D drawing regarding

specific direction. After this, from the 3D solid model of the part, we

will get directly the information required for the gating system design

like, surface area ,total volume which is required for calculating the

modulus (V/A) of casting, and other properties like weight , and mass

can be find from the Fig:3.4 and Fig: 3.5 showing a 3D model parts.

After this we have to calculate the total allowances including

shrinkage, machining allowance, and draft required whenever

necessary. Decide the Parting surface and parting direction and then

calculate the gating system design, runner riser dimensions and

position. After this calculation is over, we are going to modify the 3D

model part to get the required patterns, Fig:3.6& Fig:3.7. shows the

3D models of patterns, and thus we will get finished pattern from the

cast part model.

Now to model the Sand block and sand core whenever

necessary. So first is to calculate the dimensions of sand block, and

model it on the same pattern model on parting surface. And then by

using various Boolean Functions, we are getting the required mould

cavity (e.g. subtracting pattern from sand block model) Fig:3.8

Showing the 3D model of sand block. Now at this time all our

modelling part is over, and we have to go for analysis of modeled part.

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 Fig: 3.2. 2D Part Drawing of Straight Bar

Fig:3.3.3D model of Straight Bar Casting with gating system

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 Fig:3.4. 2D Part Drawing of Flange Bar

Fig:3.5. 3D model of Flange bar with gating system

Fig:3.6 Straight bar pattern Fig:3.7 Flanged bar pattern

Fig: 3.6 & Fig:3.7 3D part models of patterns

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 Fig:3.8. 3D model of sand block

3.2.4 Finite element modelling of Casting Process

The development of solidification process is difficult in nature and

the Simulation of such process is required in industry before it is

essentially undertaken. Finite element method is used to simulate the

heat transfer process accompanying the solidification process. The

metal and the mould along with the air gap formation is accounted in

the heat transfer simulation. deformation of the casting is caused due

to non-uniform shrinkage associated with the process. Residual

stresses are induced in the final castings. Simulation of the shrinkage

and the thermal stresses are also carried out using finite element

methods. The material behavior is considered as visco plastic. Stress

investigation of castings poses several difficulties not seen in more

traditional problems in mechanics. The residual stress formation

during castings is a consequence of various regions of a geometrically

complicated casting cooling at different rates. Stress response is the

result of coupled thermal, micro thermal and stress histories. Stress

predictions are strongly influenced by the thermal and micro

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structural histories. The accuracy of thermal and micro structural

predictions is a primary factor in the accuracy of residual stress

predictions. An overall planning of a comprehensive solidification

modelling system is shown in Fig:3.9. This Figure depicts the various

modules available in the current state-of-the-art solidification

simulation of casting processes, the information available from each

module and the interconnection between each module. The early

models of cooling of casting were straightforward heat conduction

analysis. However, the mechanics of fluid flow are important for both

mould-filling effects and physics based models of inter-dendrite

porosity formation.

Fig:3.9 Typical architecture of a comprehensive casting modelling

system [88]

This wide solidification study given an account of several

aspects of modelling of heat transfer, fluid flow and thermodynamics

in castings. Solidification kinetics including phase selection,

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nucleation and growth are now being investigated in several

laboratories. The incorporation of these principles into the more

traditional thermo-fluid models promises to enable quantitative micro

structural predictions in the near future, and predictions of

engineering properties such as tensile strength and elongation will be

possible before long. These predictions will enable product-design

engineers to evaluate the effects of non-uniform properties and defects

on the life cycle performance of components. Finally, the coupling of

mechanical analysis with thermal analysis enables the predictions of

residual stresses and distortions in castings.

3.2.5 The ProCAST System

Is a physics based computer program designed for the

calculation of fluid flow, thermal and thermo mechanical phenomena

encountered during the production of metal castings. A typical casting

is produced by pouring molten liquid metal into a suitably prepared

mould cavity containing the topology of the part to be manufactured.

As a result of heat energy extraction through the mould walls, the

liquid metal cools and solidifies producing a desired metal part. The

soundness and overall quality of cast parts is strongly affected by the

liquid metal poured in mould, flow during mould filling, and of the

time dependent temperature fields during solidification. Macro and

micro structural characteristics of the cast components are

determined by the flow and thermal history of the casting and these in

turn determine the mechanical and other physical properties of the

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material. It is based on a finite element methodology that is coupled

with a Volume of Fluid technique for the computation of mould filling.

The present study was conducted using Version 2004 of the ProCAST

System. The simulation module is the computational engine that

carries out the necessary mathematical calculations and produces

computed values of metal velocity, temperature, fraction solidified,

shrinkage porosity and the like. Finally, the ViewCAST module allows

detailed examination of the computed results.

3.2.6 Typical Steps for thermal analysis

After completing the 3D modelling in Solid Modeler Application,

save the part in STEP Format. The STEP file is imported in to
GeoMESH software. Where the solid model gets meshed and analyzed
for any possible meshing errors. After the surface mesh is generated
save the part. Now import the mesh file from GeoMESH to software, it
will show a different module in a window, select the MeshCAST
module. MeshCAST generates a 3-D tetrahedral mesh using the Finite
Element Method (FEM). A triangular surface mesh of the object is the
prerequisite for MeshCAST "tet-mesh" generation. Based upon the
IGES, PARASOLIDS, STEP, STL model, MeshCAST can generate the
triangular surface mesh. Alternatively, MeshCAST can use the surface
mesh from CAD or CAE package as input for tet-mesh generation. The
following Fig:3.10 shows the steps involved in ProCAST.

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 Fig: 3.10 Typical ProCAST Steps for thermal analysis [87]

There are six major steps in MeshCAST which are required in

order to produce a high quality tetrahedral mesh.

• Input file that is *.unv file. Every MeshCAST session will begin
with the designation.

• The surface mesh in the Meshing Environment as necessary.

MeshCAST automatically checks the input file geometry and
attempts to resolve flaws as it is loaded.

• Edit the surface mesh in the repair environment.

• In this step MeshCAST actually generates the 3-D tetrahedral

mesh of the solid model.

• View the mesh and enhance its quality, as show in (Fig:3.11

volume meshes of a part).

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 Fig:3.11. Volume mesh model in MeshCAST

Fig:3.12 Materials assignment in PreCAST:

The first operation to perform is to assign material properties to

the domains. The first domain should be selected and the desired

material properties should be selected in the database. “IS1030” steel

is selected in this case as shown in Fig. 3.12

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 Fig: 3.13 Interface menu in PreCAST

In the interface menu shown in Fig:3.13, create the interfaces

between the different Material domains and give the desired interface

heat transfer coefficients. The type of interface should be specified.

The desired interface heat transfer coefficient should be selected in the

database and assigned to the corresponding interface.

Fig:3.14 Boundary Conditions in PreCAST

The cooling of the outside of the mould with the air, as well as

the top surface of the casting should be defined in the "Boundary

Conditions" list of options. The type of boundary condition should be

selected. the "Heat" type should be selected in the list which is

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appearing as shown in Fig.3.14. Then, this "Heat" boundary condition

appears in the data base.

Fig:3.15 Gravity Sand Casting- Process Menu

The gravity should be defined in the "Process menu". This will

open the "Gravity" panel as shown in Fig.3.15. Gravity in the

appropriate direction regarding the part is set.

Fig: 3.16. Initial Conditions Menu

The initial temperature of both material domains should be

specified in the "Initial Conditions" menu. Each domain should be

selected and the initial temperature should be entered in the field as

shown in the Fig: 3.16

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 Fig: 3.17 Run Parameters Menu

Finally, the calculations parameters should be specified in the

"Run Parameters" list of options Fig: 3.17.

Fig:3.18 ProCAST solver in put window

The calculation can now be launched as show in Fig. 3.18. On

Windows, a Command window will open and the DataCAST and

ProCAST are automatically launched.

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