Casting Simulation & Case Study

Prof. Dr.-Ing. Bambang Suharno

Kuliah Pembentukan Logam
Semester Ganjil 2019-2020
Metalurgi &
Material UI Pendahuluan
 Penggunaan simulasi komputer sebagai alat bantu
dalam simulasi casting dimulai pada tahun 80an
 Pada dasarnya perhitungan berdasarkan pada
computasi FEM, FDM atau FVM
 Familiar brand casting simulation seperti
Magmasoft, ProCAST, Stefan, SolidCast
 Z-Cast (Korea)
Metalurgi &
Material UI Konsep Desain Casting
Metalurgi &
Material UI Langkah Dalam pengembangan suatu Produk casting

 Desain awal produk

 Assesmen kelayakan casting produk
 Assesmen quality yang dibutuhkan
 Membuat desain riser dan gating sistem
 Pembuatan pattern/pola
 Uji coba casting
Casting
 Proposal perubahan untuk castability yang lebih baik simulation
 Perubahan desain produk, riser dan gating sistem
 Test Casting
 Proses produksi
 Inspeksi akhir
 Inspeksi oleh pihak costumer
Metalurgi &
Material UI Contoh Casting Simulation (ProCast)

Prediksi porositas
Hasil test X-Ray
Metalurgi &
Material UI

Air Trapped
Metalurgi &
Material UI
Direct observation of casting process
Metalurgi &
Fluid Flow Analysis Module
Material UI
 Uncompressible viscous fluid
flow
 Transient heat and mass
transfer

 Gravity sand casting, HPDC,

LPDC, Tilt casting, and
Investment casting
Metalurgi &
Solidification Analysis Module
Material UI
 3D Transient Heat Transfer
and Solidification Analysis
 Temperature Recovery Method
(Latent Heat)
 General Sand Casting and
Investment Casting
 Cycle Analysis Module (Jika Casting Berulang/ HPDC)
Metalurgi &
Material UI
 Cooling line design of mold
 Decision of cycle time
 Forecast heat accumulation in
mold and control mold
temperature
Casting Simulation Case
Metalurgi &
Material UI CASTING SIMULATION CASE STUDY
 Oil Pan
 Small Turbine Casing
Metalurgi &
Material UI Oil Pan Layout

Oil Level

Install Bolt Hole

Block Cyl sett part

Strainer Hole
Metalurgi &
Material UI [1] Block Cycl. Sett Part
Metalurgi &
Material UI [13.7] Strainer Hole
Metalurgi &
[1] Block Cycl.
Sett Part
Material UI
Metalurgi &
Material UI
Type Porositas

Gas
Shringkage
pororsity
pororsity

Gas & Shringkage

porosity
Metalurgi &
Material UI

Thin section,
higher cooling
rate
Metalurgi &
Material UI HPDC Casting parameter
 Material : ADC 12
 Material Dies : SKD 61
 Temperatur pouring : 655oC
 Temperatur dies : 110oC
Metalurgi &
Material UI 3D Model

Original Desain Modifikasi Desain

Metalurgi &
Material UI Persentase Filling 20%
Modifikasi

Original
Metalurgi &
Material UI Persentase Filling 50%
Modifikasi

Original
Metalurgi &
Material UI
Persentase Filling 94%
Modifikasi

Original
Metalurgi &
Material UI SMALL TURBINE CASING
Metalurgi &
Material UI 3D Model
Metalurgi &
Material UI Upper Inlet
Metalurgi &
Material UI
Metalurgi &
Material UI 3D Model Revision
Metalurgi &
Material UI Simulation Result
Metalurgi &
Material UI Casting Product
Metalurgi &
Material UI
Al Wheel Casting
Metalurgi &
Material UI Wheel - Low Pressure DC
Metalurgi &
Material UI
Input Parameter
Metalurgi &
Material UI

Air
Water cooling
(Sprue, hub)

Cavity

Mold(skd61) Air cooling

(Spoke, hub)
Sprue bush
(SCM440)

Cooling Channel
Metalurgi &
Material UI

Before

Hot spot

defect
Metalurgi &
Material UI

Air

Direction of
Solidification

Chill & Ceramic Wool

Metalurgi &
Material UI
Al Wheel
Occur shrinkage defects owing
to improper cooling line design

Chill & Ceramic Wool

No defect casting design by

inducing directional solidification

Before After
6min 4min
Production speed
30sec 50sec
Cooling channel
Defective proportion 8% 1.7%