EXPERIENCE OF INDUSTRIAL APPLICATION OF COMMERCIAL SOFTWARE FOR CASTING PROCESSES SIMULATION

摘要

A typical new casting startup procedure includes the getting system designing, finite-element mesh generation, selection casting process parameters in accordance with the foundry requirements specification, the casting process simulation, casting design approval and standard casting pattern assembling. Despite of the large available experience, there are no commercial software fully met the demands of the industrial application. A quality of the physical model realized in the simulation software is the result of compromise between the model adequacy and reasonable calculation time. Any porosity model contains parameters which have to be determined from experimental data. Usually, these parameters depend on thermal conditions of solidification, such as metal cooling rate or thermal gradient. Therefore, in theory, shrinkage model parameters are different for the different castings and casting processes. A technique of coupled application of commercial software ProCast and Poligon to the manufacturing of the large scaled turbine blades are presented.