At present, the application of computer in simulated casting process mainly focuses on the following aspects:
(1) Simulation of filling and solidification process
On the basis of a large number of basic research work, the numerical simulation of casting filling process has gradually reached the practical level. Many simulation algorithms for mold filling and solidification process have been studied, such as parallel algorithm, three-dimensional finite element method, three-dimensional finite difference method, numerical method and analytical method. It mainly focuses on mold filling simulation of casting, and its development trend is to assist in the design of gating system.
(2) Shrinkage prediction
Numerical simulation of temperature field and prediction of shrinkage defects is the core content of casting CAE. Its ultimate purpose is to optimize the process design and achieve quality prediction. The prediction of shrinkage and porosity based on the simulation of temperature field is an important part of the research.
(3) Stress simulation of solidification process
It is mainly used to simulate the residual stress and residual deformation of the casting. The numerical simulation of the stress field is the core of the numerical simulation of the stress field when the liquid and solid coexist. Many casting defects such as shrinkage porosity, shrinkage cavity and hot crack occur at this stage. Because it is very difficult to measure the mechanical properties of liquid-solid coexisting state, the mechanical model of this stage has not been completely established at present, so it is still difficult to simulate the whole casting process.
(4) Microstructure simulation of solidification process
Microstructure simulation is a complex process, which is more difficult than solidification and mold filling process simulation. In recent years, various microstructure simulation methods have emerged one after another, and have become one of the research hotspots in material science. Although these methods can accurately simulate the solidification structure of the alloy to a certain extent, due to the complexity of the actual solidification process, these methods have made many assumptions, so there is still a certain distance from the actual solidification structure simulation of the casting.
(5) Numerical simulation in other fields
With the development of pillar and basic industries such as automobile, aviation, aerospace and national defense, the precise forming technology of new materials (aluminum, zinc-magnesium and other high specific strength alloys) must be carried out. These new technologies must be based on the simulation of the forming process to achieve the best results with high quality, short cycle and low cost. This has led to the development of numerical simulation of precision casting. The forming methods of precision casting mainly include: low pressure casting, pressure casting, gravity casting, lost foam casting, squeeze casting, centrifugal casting, investment casting, electromagnetic casting and semi-solid casting.