Simulation software for mold filling and solidification process of casting

The development of numerical simulation of sheet metal flow in 1987 is limited by the development of computer simulation of sheet metal flow. In 1987, Wang Junqing, a Chinese scholar, went to the University of science and technology in Denmark as a visiting scholar. He completed the transformation of the simulation of the filling process from two-dimensional to three-dimensional, and added the calculation of three-dimensional heat transfer in the simulation process. On the basis of these, he also compared the two-dimensional SMAC, sola VOF and simple algorithms. The results of all these calculations show that under the condition of almost no difference in all calculation accuracy, SOLA-VOF is obviously superior to the other two algorithms in computing speed.

In 1987, h.j.lin and w.s.hwang combined Mac and sola method to apply to three-dimensional calculation program, and developed simulation software on this basis. Basically, after that, the simulation of casting filling process has entered the three-dimensional world. In 1988, h.j.lin and w.s.hwang introduced the energy conservation equation of the fluid world in the mold filling process simulation of castings, and realized the combined simulation of temperature field and flow field, with remarkable results. In the same year, R.A. stoehr and C.Wang also realized the coupling calculation of temperature field and flow field, Moreover, in the process of simulating liquid metal filling, the variation of thermophysical parameters with temperature and the influence of solidification shrinkage on the filling simulation results are considered, and the phenomena such as cold shut are successfully simulated.

In 1992, G. Upadhya and A.J. Paul regarded the flow of liquid metal and the heat transfer and solidification in the mold filling process as a whole, and combined with the theory of solidification dynamics, they effectively predicted the defects in the casting process. In recent years, casting researchers have considered more and more factors in the numerical simulation of mold filling process, and the simulation process is closer and closer to the actual production environment, and the effect is more and more obvious. At that time, stress simulation was difficult to realize and existed only in the theoretical stage. Until 1993, Toyota Motor Corporation of Japan carried out residual stress analysis on the engine block and wheel Yi on the computer, which made the application of stress field simulation in casting process practical and feasible.

At the same time, there are many software to simulate the casting process abroad, which have attracted the attention of casting researchers. In 1989, the 7th International Foundry Expo was held in Germany. At this conference, MAGMAsoft, as the world’s first commodity software for casting numerical simulation, was born. It is a simulation software researched and developed by Professor Sahm of Aachen University in Germany, with the analysis of temperature field in casting process as the main core. Subsequently, many excellent foundry CAE commercialization software appeared, such as ProCAST in the United States, CastCAE in Finland, simulor in France, frocast in Spain, etc. In terms of function, these simulation software can simulate the flow field, temperature field and stress field of many processes such as sand casting, metal mold casting and pressure casting, and can predict the casting defects such as shrinkage cavity, porosity and crack and the organization of each part of the casting, so as to improve the accuracy of simulation analysis, so as to be closer to the actual production.

Compared with foreign countries, the research on computer numerical simulation of casting process in China started relatively late, but it has also made some development. In 1978, during the research on the casting process of large turbine blades of Gezhouba hydropower station, Wang Junqing and Zhang Yi, foundry workers of Shenyang Foundry Research Institute, carried out the computer simulation research on the temperature field during the solidification of blade castings. At the same time, casting workers such as Jin Junze from Dalian University of technology also numerically simulated and analyzed the temperature field of the solidification process of large marine copper propeller castings. In terms of flow field simulation, in 1987, Wang Junqing of Shenyang Foundry Research Institute took the lead in carrying out research and made some progress. Later, Jing Tao, Pei Qingxiang, Qiu Wei and Gao Zhiqiang of Tsinghua University, Sun Xun and Chang Qingming of Harbin Institute of technology, Chen Liliang and Yuan Haoyang of Huazhong University of technology, Hou Hua and Xu Hong of Zhongbei University have successively carried out a large number of detailed and quite in-depth research and development work. At present, The software of Tsinghua University, the software developed by Zhongbei University and the software of Huazhong University of science and technology have been popularized and applied in some domestic foundry enterprises.

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