The development of sand casting process simulation technology is closely related to the development of computer technology. Since 1962, scientists first calculated the heat transfer of sand casting solidification process based on digital computer and finite difference method, all kinds of commercial simulation software of sand casting have played an important role in predicting sand casting defects, analyzing sand casting quality and optimizing sand casting process. These include ProCAST in France, magma in Germany, CastCAE in Finland, Forcast in Spain, casttem in Japan, simulor in France and novasolid in Sweden. These software can simulate the flow field, temperature field and stress field of sand casting, metal mold casting and precision casting, and predict the defects such as sand inclusion, shrinkage porosity, shrinkage cavity, crack, deformation and microstructure of various parts.
China’s sand casting process simulation technology started late and developed rapidly. The more mature commercial software includes ft star of Tsinghua University, Huazhu CAE of Huazhong University of science and technology, sriftcast of Shenyang Casting Research Institute, etc. some of its functions are equivalent to foreign software and are applied to many domestic casting manufacturers.
ProCAST software is based on the numerical simulation method of finite element method. Based on the conservation of heat, mass and momentum in the process of heat transfer and flow, it calculates the temperature, solid rate, pressure, void rate and other data of each unit at different times and positions, and predicts all kinds of sand casting defects. ProCAST software can carry out flow heat conduction stress coupling analysis, including eight modules, that is, in addition to the basic modules such as flow, heat transfer, stress analysis and mesh generation, it also includes modules such as thermal radiation analysis, microstructure analysis, electromagnetic induction analysis and reverse solution, which are suitable for different processes and customer needs. The remarkable characteristics of ProCAST simulation software are repeatability, virtual test, great flexibility, powerful simulation function and humanized interface.
CSR Changjiang Company has introduced the ProCAST sand casting process simulation software of French ESI company. Based on the cooperation project, ProCAST software is used to simulate and optimize the process of hook body and tongue.