Design Optimization of Feeding System and Solidification Simulation for Cast Iron

The optimal design of a casting feeding system is considered. The riser topology is systematically modified to minimize the riser volume, while simultaneously ensuring that no defect appears in the product. In this approach, we combine finite-difference analysis of the solidification process with evolutionary topology optimization to systematically improve the feeding system design. The outstanding features of the presented method are: its efficiency, ease of implementation and simplifying definition of the initial design. The efficiency and capability of the presented method are supported by illustrative examples.

Optimal riser design in sand casting process with evolutionary topology optimization

A medical-axes-based interpolation method for solidification simulation

Casting simulation programs can be used by foundry engineers for quality assurance and yield optimisation without shop-floor trials, as well as by product engineers for analysing and optimising the feedability of a casting during design phase itself. For widespread application, the simulation programs should require little domain experience, and they should be fast, reliable, easy-to-use, and economical. These goals can be achieved by automating some of the tasks involved: identifying the location of a feeder, calculating its minimum size, creating its solid model, attaching the feeder model to the casting, carrying out solidification simulation, predicting quality and estimating the yield. This paper describes the underlying algorithms, and their implementation in a software program. Two industrial cases of large steel castings show how simulation facilitates troubleshooting and elimination of defects by minor changes to part design coupled with improved methoding of casting.

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Feedability Analysis and Optimisation Driven by Casting Simulation

The optimal design of a casting feeding system is considered. The problem is formulated as the volume constrained topology optimization and is solved with the finite element analysis, explicit design sensitivity, and numerical optimization. In contrast to the traditional topology optimization where the objective function is defined on the design space, in the presented method, the design space is a subset of the complement of the objective function space. To accelerate optimization procedure, the nonlinear unsteady heat transfer equation is approximated with a Poisson-like equation. The feasibility of the presented method is supported with illustrative examples.

Optimal riser design in sand casting process by topology optimization with SIMP method I: Poisson approximation of nonlinear heat transfer equation

This paper briefly reviews various geometry-driven methods for analysing the solidification process of a casting, which offer the advantage of being faster and less dependent on material properties...

M. N. Srinivasan

Papers

Casting solidification analysis by modulus vector method