Title

COMPARISON BETWEEN NUMERICAL SIMULATION AND EXPERIMENTAL RESULTS OF PERMANENT MOLD CASTING ACCORDING TO ASTM B108

COMPARISON BETWEEN NUMERICAL SIMULATION AND EXPERIMENTAL RESULTS OF PERMANENT MOLD CASTING ACCORDING TO ASTM B108

Authorship

FOLLE, LUÍS FERNANDO; LIMA, TIAGO NUNES; SANTOS, MATHEUS PASSOS SARMENTO; CALLEGARI, BRUNA; SILVA, LEONARDO OLIVEIRA PASSOS DA; COELHO, RODRIGO SANTIAGO

FOLLE, LUÍS FERNANDO

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LIMA, TIAGO NUNES

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SANTOS, MATHEUS PASSOS SARMENTO

I am this author

CALLEGARI, BRUNA

I am this author

SILVA, LEONARDO OLIVEIRA PASSOS DA

I am this author

COELHO, RODRIGO SANTIAGO

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DOI

10.5151/2594-5300-40754

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Abstract

METAL CASTING CAN BE ACCOMPANIED BY THE OCCURRENCE OF DEFECTS SUCH AS MICRO- AND MACRO-POROSITY, ENTRAPPED GAS BUBBLES, CONTRACTION CAVITIES, HOT CRACKING, OXIDE BIOFILMS AND TURBULENT FLOW OF LIQUID METAL, DEFECTS INHERENT TO THIS MANUFACTURING PROCESS. HOWEVER, THERE ARE FINITE ELEMENT SOFTWARES THAT CAN PREDICT THESE DEFECTS IN THE DESIGN STAGE OF CAST PARTS TO HELP AVOID THEM. THE AIM OF THIS PAPER IS TO COMPARE RESULTS OBTAINED BY TWO DIFFERENT FINITE ELEMENT SOFTWARES – PROCAST (ESI GROUP) AND INSPIRE CAST (ALTAIR) – WITH EACH OTHER AND WITH EXPERIMENTAL A356 ALUMINUM CASTING RESULTS WITH FOCUS ON THE MAIN CASTING DEFECTS USING A STANDARDIZED PERMANENT MOLD. BOTH SOFTWARES ARE EXTENSIVELY USED IN THE INDUSTRY WITH THE PURPOSE OF PRODUCING DEFECT-FREE CAST PARTS. RESULTS INDICATE THAT BOTH SOFTWARES PROVIDE SIMILAR RESULTS WITH RESPECT TO CASTING DEFECTS, IN ACCORDANCE WITH EXPERIMENTAL OBSERVATIONS, BUT SOLIDIFICATION TIME VARIED CONSIDERABLY, ESPECIALLY WHEN PROCAST WAS USED.

METAL CASTING CAN BE ACCOMPANIED BY THE OCCURRENCE OF DEFECTS SUCH AS MICRO- AND MACRO-POROSITY, ENTRAPPED GAS BUBBLES, CONTRACTION CAVITIES, HOT CRACKING, OXIDE BIOFILMS AND TURBULENT FLOW OF LIQUID METAL, DEFECTS INHERENT TO THIS MANUFACTURING PROCESS. HOWEVER, THERE ARE FINITE ELEMENT SOFTWARES THAT CAN PREDICT THESE DEFECTS IN THE DESIGN STAGE OF CAST PARTS TO HELP AVOID THEM. THE AIM OF THIS PAPER IS TO COMPARE RESULTS OBTAINED BY TWO DIFFERENT FINITE ELEMENT SOFTWARES – PROCAST (ESI GROUP) AND INSPIRE CAST (ALTAIR) – WITH EACH OTHER AND WITH EXPERIMENTAL A356 ALUMINUM CASTING RESULTS WITH FOCUS ON THE MAIN CASTING DEFECTS USING A STANDARDIZED PERMANENT MOLD. BOTH SOFTWARES ARE EXTENSIVELY USED IN THE INDUSTRY WITH THE PURPOSE OF PRODUCING DEFECT-FREE CAST PARTS. RESULTS INDICATE THAT BOTH SOFTWARES PROVIDE SIMILAR RESULTS WITH RESPECT TO CASTING DEFECTS, IN ACCORDANCE WITH EXPERIMENTAL OBSERVATIONS, BUT SOLIDIFICATION TIME VARIED CONSIDERABLY, ESPECIALLY WHEN PROCAST WAS USED.

Keywords

Casting; A356 aluminum alloy; Numerical simulation; Inspire Cast software, ProCast software.

Casting; A356 aluminum alloy; Numerical simulation; Inspire Cast software, ProCast software.