Realization of numerical simulation of lost foam casting process with ProCAST software

ProCAST is a professional computer simulation software for optimizing lost foam casting process. We can use ProCAST simulation software to simulate and analyze the filling field and temperature field in the forming process of lost foam casting, predict the location and quantity of lost foam casting defects, and optimize the lost foam casting process scheme, so as to shorten the production cycle and reduce the production cost. ProCAST adopts the finite element numerical calculation method. With the current powerful computer technology, according to various theories of metal flow, it can simulate the temperature field and flow field, and calculate the temperature and flow field of castings in the process of mold filling and solidification, so as to achieve the purpose of predicting the location and size of defects.

1.Application scope of ProCAST software

(1) Applicable lost foam casting method

ProCAST has many applicable lost foam casting methods, which are not only suitable for ordinary casting, such as traditional sand casting; It is also suitable for special casting, such as pressure casting, gravity casting, lost foam casting, investment casting, thixotropic casting, thixotropic forming, shell casting, low pressure / high pressure casting and other casting methods.

(2) Applicable lost foam casting materials

ProCAST is also applicable to many lost foam casting materials, which are almost applicable to any alloy, such as ordinary ferroalloy and steel alloy, as well as various nickel based alloys, zinc based alloys, titanium based alloys, copper based alloys, magnesium based alloys, aluminum based alloys and cobalt based alloys, as well as polymers.

2.ProCAST software simulation analysis capability

ProCAST has strong simulation and analysis ability. It can simulate the flow field and temperature field in the process of lost foam casting and the problems that will occur in the process of lost foam casting. It can let us clearly see the whole lost foam casting filling and solidification process. In this way, we can find the cause of defects and optimize the lost foam casting Process, And guide the actual production.

3.Characteristics of ProCAST

ProCAST adopts the finite element method. Compared with the finite difference method, the finite element method is more flexible, especially suitable for simulating various physical phenomena in the forming process of complex lost foam castings. Its advantages are summarized as follows:

(1) With good description ability, the finite element method can accurately describe the surface, while the finite difference method can only simplify the description of the surface.

(2) Local mesh refinement can be carried out, and the finite element method will not affect the refinement process on the refurbishment model like the finite difference method. In this way, compared with the finite difference method, the number of elements and nodes is significantly less.

(3) When using elastic, elastic-plastic and elastic viscoplastic models for thermal coupling and stress analysis, the finite difference method can not carry out stress analysis because the mesh can not be deformed, so it can only use the finite element method.

(4) It can accurately simulate the flow field in the mold filling process of lost foam castings. This is because the finite element method can accurately describe the surface boundary, while the finite difference method can not accurately describe the surface boundary of lost foam casting because the section is serrated.

(5) It can accurately deal with the radiation heat transfer problem, while the finite difference method can not deal with the complex radiation problem because it can not accurately describe the outer surface and corresponding orientation, and can not calculate the viewing angle coefficient and shadow effect.

The procedure of mesh creation and calculation (including the procedure of mesh creation and calculation of finite element model) by Prost software, including the procedure of mesh generation and calculation of the initial mesh parameters, etc.

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