Simulation of casting solidification

Chapter One
General Introduction
1.1 Introduction
Casting processes are among the oldest methods of manufacturing various
objects and functional parts. Casting dates back to around 4000 B.C. when copper
arrowheads were made [1]. Casting processes basically involve the introduction of a
molten metal into a mold cavity, where, upon solidification, the metal takes on the
shape of the mold cavity [2].
The casting process is capable of producing intricate shapes, both internal and
external, in a single piece. Very large or hollow parts, which would be very difficult or
expensive to make by other methods, can be mass produced economically, using proper
casting techniques [3].
The process of mould design in the foundry industry has long been based on the
intuition and experience of foundry engineers and designers. To bring the industry to a
more scientific basis the design process should be integrated with scientific analysis
such as fluid flow, heat transfer and stress analysis. Perhaps the most effective way to
do this is with the aid of computer aided optimization (CAO). Starting with the original
design, a computer model is used to simulate the casting process. Given a set of defect
criteria, defects can be predicted that suggest modifications to the original design. After
several iterations of this design cycle an optimum design, free of defects should be
produced. From this procedure, it will be possible to determine whether a given mould
design will produce a sound casting without having to discover this in the foundry
through the usual trial and error process, which can be very tedious, time consuming,
and expensive.
The major limitations of casting in comparison with other shaping processes,
such as forging, are lower toughness and ductility, and porosity in the cast product. The
occurrence of porosity during metal solidification is one of the major factors that impact
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the quality of metal casting. The size, location and volume fraction of porosity have
been shown to have negative effect on surface finish and mechanical properties, such as
tensile strength and fatigue life [4].
1.2 Aim of Thesis
Due to bad design of casting system, the solidification shrinkage, causes two
types of defects. First the shrinkage porosity, which can be identified by using the
defect criteria as indicator to their development or not. Second the shrinkage cavities,
which may be treated by other methods to allocate the hot spots.
The aim of Thesis is to get distribution of temperatures; history of temperature;
and thermal structure for both casting and mold, so the identification of hot spots, or
last freezing regions is accomplished by drawing the solidification contours. If the
liquidus or solidus contours are enclosed and make loops, this means, that there are no
feeding liquid metal will reach the internal regions of these loops, so the continuity of
solidification and contraction inside these loops will create cavities there. By this way
the location of cavities will be identify.
1.3 Strategy of Thesis
This thesis contains five chapters. Chapter one is the general introduction, which
consists of the aim of the project and the present paragraph. Chapter two is the
theoretical part, which consists of the principles of nucleation, growth, solidification
and shrinkage. Also, it contains the solidification modeling and its requirements
.Chapter three contains the processing part which is divided into two parts. The first
part concerns the real casting of a specified casting, while the second part concerns the
theoretical simulation by the finite difference technique of this casting. Chapter four
contains the discussion of the simulated solidification steps and the mechanism of
cavity formation. Also it contains the verification of the simulation by the comparison
between the location of the cavity in the real casting and in simulated one. Chapter five
contains the main conclusions which are extracted from this study and some
suggestions for future investigators.