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    Casting Simulation & Study Case

    Uploaded by

    Rosalina Kezia
    1. The document discusses casting simulation software and its use in designing castings and predicting defects. 2. Two case studies are presented: simulation helped optimize the design of an oil pan casting to eliminate porosity, and redesign of a turbine casing inlet to improve filling. 3. Simulation was also used to optimize cooling line design in an aluminum wheel casting to induce directional solidification and eliminate shrinkage defects.

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    Casting Simulation & Study Case

    Uploaded by

    Rosalina Kezia
    142 views37 pages
    1. The document discusses casting simulation software and its use in designing castings and predicting defects. 2. Two case studies are presented: simulation helped optimize the design of an oil pan casting to eliminate porosity, and redesign of a turbine casing inlet to improve filling. 3. Simulation was also used to optimize cooling line design in an aluminum wheel casting to induce directional solidification and eliminate shrinkage defects.

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    3. Casting Simulation & Study Case

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    1. The document discusses casting simulation software and its use in designing castings and predicting defects. 2. Two case studies are presented: simulation helped optimize the design of an oil pan casting to eliminate porosity, and redesign of a turbine casing inlet to improve filling. 3. Simulation was also used to optimize cooling line design in an aluminum wheel casting to induce directional solidification and eliminate shrinkage defects.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    142 views37 pages

    Casting Simulation & Study Case

    Uploaded by

    Rosalina Kezia
    1. The document discusses casting simulation software and its use in designing castings and predicting defects. 2. Two case studies are presented: simulation helped optimize the design of an oil pan casting to eliminate porosity, and redesign of a turbine casing inlet to improve filling. 3. Simulation was also used to optimize cooling line design in an aluminum wheel casting to induce directional solidification and eliminate shrinkage defects.

    Copyright:

    © All Rights Reserved
    Download as PPTX, PDF, TXT or read online from Scribd
    Download as pptx, pdf, or txt
    of 37
    At a glance
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    The document discusses casting simulation techniques and case studies.

    Some common casting simulation software mentioned are Magmasoft, ProCAST, Stefan, SolidCast and Z-Cast.

    The steps involved in casting product development are initial design, feasibility assessment, quality requirements assessment, riser and gating system design, pattern making, test casting, proposal for improved castability, product and system redesign, test casting, production process, final and customer inspections.

    Casting Simulation & Case Study

    Prof. Dr.-Ing. Bambang Suharno


    Kuliah Pembentukan Logam
    Semester Ganjil 2019-2020
    Metalurgi &
    Material UI Pendahuluan
     Penggunaan simulasi komputer sebagai alat bantu
    dalam simulasi casting dimulai pada tahun 80an
     Pada dasarnya perhitungan berdasarkan pada
    computasi FEM, FDM atau FVM
     Familiar brand casting simulation seperti
    Magmasoft, ProCAST, Stefan, SolidCast
     Z-Cast (Korea)
    Metalurgi &
    Material UI Konsep Desain Casting
    Metalurgi &
    Material UI Langkah Dalam pengembangan suatu Produk casting

     Desain awal produk


     Assesmen kelayakan casting produk
     Assesmen quality yang dibutuhkan
     Membuat desain riser dan gating sistem
     Pembuatan pattern/pola
     Uji coba casting
    Casting
     Proposal perubahan untuk castability yang lebih baik simulation
     Perubahan desain produk, riser dan gating sistem
     Test Casting
     Proses produksi
     Inspeksi akhir
     Inspeksi oleh pihak costumer
    Metalurgi &
    Material UI Contoh Casting Simulation (ProCast)

    Prediksi porositas
    Hasil test X-Ray
    Metalurgi &
    Material UI

    Air Trapped
    Metalurgi &
    Material UI
    Direct observation of casting process
    Metalurgi &
    Fluid Flow Analysis Module
    Material UI
     Uncompressible viscous fluid
    flow
     Transient heat and mass
    transfer

     Gravity sand casting, HPDC,


    LPDC, Tilt casting, and
    Investment casting
    Metalurgi &
    Solidification Analysis Module
    Material UI
     3D Transient Heat Transfer
    and Solidification Analysis
     Temperature Recovery Method
    (Latent Heat)
     General Sand Casting and
    Investment Casting
    Cycle Analysis Module (Jika Casting Berulang/ HPDC)
    Metalurgi &
    Material UI
     Cooling line design of mold
     Decision of cycle time
     Forecast heat accumulation in
    mold and control mold
    temperature
    Casting Simulation Case
    Metalurgi &
    Material UI CASTING SIMULATION CASE STUDY
     Oil Pan
     Small Turbine Casing
    Metalurgi &
    Material UI Oil Pan Layout

    Oil Level

    Install Bolt Hole

    Block Cyl sett part


    Strainer Hole
    Metalurgi &
    Material UI [1] Block Cycl. Sett Part
    Metalurgi &
    Material UI [13.7] Strainer Hole
    Metalurgi &
    [1] Block Cycl.
    Sett Part
    Material UI
    Metalurgi &
    Material UI
    Type Porositas

    Gas
    Shringkage
    pororsity
    pororsity

    Gas & Shringkage


    porosity
    Metalurgi &
    Material UI

    Thin section,
    higher cooling
    rate
    Metalurgi &
    Material UI HPDC Casting parameter
     Material : ADC 12
     Material Dies : SKD 61
     Temperatur pouring : 655oC
     Temperatur dies : 110oC
    Metalurgi &
    Material UI 3D Model

    Original Desain Modifikasi Desain


    Metalurgi &
    Material UI Persentase Filling 20%
    Modifikasi

    Original
    Metalurgi &
    Material UI Persentase Filling 50%
    Modifikasi

    Original
    Metalurgi &
    Material UI
    Persentase Filling 94%
    Modifikasi

    Original
    Metalurgi &
    Material UI SMALL TURBINE CASING
    Metalurgi &
    Material UI 3D Model
    Metalurgi &
    Material UI Upper Inlet
    Metalurgi &
    Material UI
    Metalurgi &
    Material UI 3D Model Revision
    Metalurgi &
    Material UI Simulation Result
    Metalurgi &
    Material UI Casting Product
    Metalurgi &
    Material UI
    Al Wheel Casting
    Metalurgi &
    Material UI Wheel - Low Pressure DC
    Metalurgi &
    Material UI
    Input Parameter
    Metalurgi &
    Material UI

    Air
    Water cooling
    (Sprue, hub)

    Cavity

    Mold(skd61) Air cooling


    (Spoke, hub)
    Sprue bush
    (SCM440)

    Cooling Channel
    Metalurgi &
    Material UI

    Before

    Hot spot

    defect
    Metalurgi &
    Material UI

    Air

    Direction of
    Solidification

    Chill & Ceramic Wool


    Metalurgi &
    Material UI
    Al Wheel
    Occur shrinkage defects owing
    to improper cooling line design

    Chill & Ceramic Wool

    No defect casting design by


    inducing directional solidification

    Before After
    6min 4min
    Production speed
    30sec 50sec
    Cooling channel
    Defective proportion 8% 1.7%

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