Development prospect of computer simulation technology for casting process

Although a large number of valuable achievements have been made in the past few decades, some important research still puzzles researchers. As the only way to develop the foundry industry, computer simulation should have the following characteristics in the future development of simulation software:

  1. It must be able to predict the problems that can occur in the process, the positions of defect pores, shrinkage holes, cold shuts, inclusions, sand erosion and hot cracks in the casting, and how to solve these problems in an appropriate way on the premise of comprehensively considering different production details.
  2. It is necessary to consider more influencing factors in the simulation, establish a more perfect macro and micro unified model that conforms to the actual situation, and develop a more perfect CAD software that not only focuses on the casting process but also has friendly visual pre-processing and post-processing interface graphics.
  3. It is necessary to further improve the model, optimize the algorithm, formulate accurate and efficient numerical calculation methods, and establish an accurate and comprehensive physical property database of solidification transport.
  4. For a long time in the future, solidification simulation, as a powerful tool, still needs to be used by process designers with practical experience to play its role and potential.
  5. In the networked environment, the parallel integration of design, simulation, manufacturing, evaluation and other links into one system should be the key development direction, and also a scientific method for rapid product development and improving casting quality.
  6. The simulation of casting solidification process is a very complicated process. If the numerical simulation of solidification is carried out only from the energy equation, ignoring the transient changes of the flow field and temperature field in the mold filling or simplifying the assumptions, the accuracy of the calculation of the temperature field in the solidification process will be greatly affected. At the same time, the flow of molten metal during mold filling is closely related to many casting defects, such as cold shut, gas entrainment, shrinkage porosity and macro segregation.