RNariman Metal-Casting Consulting, Inc.

Example of simulation work.

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

Simulation of casting solidification in a sand mold using the FEM process modeling program ProCast. First iteration using original geometry.

The adjacent macroporosity plot shows three disctinct areas of shrinkage porosity in this part.

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

Based on the Simulation results, the Foundry recommended the addition of two ribs to de original design. The change was approved by the customer.

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

Model preparation for actual production run simulation.

Rigged Part with

risering system.

Rigged Part with

risering system.

Part and Sand Mold Assembly

Part and Sand Mold Assembly

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

ProCast Temperature-Time plot.

Heat Flow is directional towards the three risers. This a desirable condition.

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

Solid Fraction fringe plot sequence . The void zones indicate solid metal. The Yellow zone is liquid metal at the solidification temperature. Isolated yellow spots unattached to risers would be an indication of porosity.

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

Macroporosity plot.

All porosity is contained in the three risers. The risers will be removed, leaving a sound castings.

Porosity found in the original simulation has been eliminated.

High Alloy Foundry. Interactive Casting Engineering via CAD Model Transfer.

Porosity found in the original simulation has been eliminated.

Sectioned sample casting.

No evidence of macro or micro porosity after dye penetrant inspection of the cut surfaces.

No integrity problems were found in X-Ray as well.