engleski

Numerical simulation in optimization of thin-walled EN-GJL-200 casting

Implementation of new strategies and concepts such as "Near net shape castings" and "Right for the first time" represent an imperative for nowadays foundry production. High material utilization, with minimal number of forming operations and defects avoiding is the main goal for casting producers. Therefore, numerical simulation as a part of CAD/CAE technologies represents an indispensable tool for achieving competitiveness on global market. Numerical simulation of casting poring and solidification represents a description of physical phenomena based on mathematical model. The application of computer numerical simulations, which are based on complex and comprehensive mathematical models such as Fourier law, found its significant application in consideration of thermal processes in the foundry. Numerical simulation enables analogical display of metallurgical processes by calculation and graphical disposition of the process from the pouring to the final casting solidification. Solidification process is very complex process which comprehends knowledge related to material and technology behaviour and interactions. Complexity of metal casting consists from element interactions and mass transfer during solidification, and technological development including heat transfer. The most useful numerical method is finite difference method due to its simplicity, but the finite element method is more accurate and does not have any limitation with respect to the complexity of geometric shapes. The focus of this investigation was optimization of pouring and solidification process of thin-walled EN-GJL-200 casting using numerical simulation. Complex geometry of thin-walled casting represents the challenge due to crusted parts and stress bending of casting in existing technological set up. Numerical simulation optimization reveals changes in technological parameters of gating system, venting system and support. Optimization enables even filling of castings in order to prevent an extensive thermal overload and consequently stress of particular parts of castings.

numerical simulation, EN-GJL-200, thin-wall casting, solidification

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