Localization of Casting Defects,Prediction of Structural and Mechanical Casting Properties and Optimization of Casting Technologies with MAGMAsoft

摘要

The investigations in the field of computer simulation and optimization of different casting technologies are performed. The well-known world famous high-integrated commercial program MAGMAsoft is used. Its fundamental and comprehensive mathematical models implemented in different software modulus are applied to simulate the main physical processes cared out during the casting formation. Special effective methods are developed to localize important casting defects and to predict structural and mechanical properties of the casting. The capabilities of the software to predict casting structure and casting properties are illustrated on some enclosed examples. The different casting methods like gravity casting, low pressure die casting, counter pressure die casting and high pressure die casting are treated. Two different approaches are offered to optimize casting technologies and obtain high quality castings. The first of them uses a classical interactive and iterative procedure. Follow it the most important parameters (geometry and allocation of the used chills, feeders and insulation materials, as well as their thermo-physical parameters, etc.) are varied to obtain high quality casting -casting with 100% feeding in the entire volume and without porosity and defects. The second one is based on a special target function constructed in expanded parameter space to optimize whole process of casting production. The varied parameters include: number, configuration and switching/off times of the cooling channels; duration of the casting cycle; temperature regime of the mould; temperature stresses in the mould; energy consumption. The optimal solution is obtained like global or local minimum of this target function in the set of mentioned parameters.