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Towards optimization of stress simulation in real casting-mould systems

Ignaszak Z.

Archives of Foundry Engineering

2010

Vol. 10, iss. 4

69--76

The simulation codes using from many years by foundry industry such e.g. Magmasoft, NovaFlow&Solid and ProCast, contain also the thermo-mechanical modules permitting the estimation of mechanical stresses/deformations in casting during its cooling. It is also known that these modules are rarely used because of the very limited thermo-mechanical database especially for ceramic materials such as foundry sand mould. These technologies – castings pouring in non-permanent sand moulds, particularly iron alloys are most often applied in foundry. In our study the method of evaluating the algorithms quality applied in thermo-mechanical phenomena models based on parameters sensitivity testing from the proper database of the simulation system was used [1]. The comparative analyses of both experimental and virtual results were realized (by stress estimation). Methodology of experimental research was resemble to that described in provided that the applied gray cast iron casting of stress bars (grid) were casted in sand mould bonded by organic resins. Also the usefulness of author's method called Hot Distortion Plus® consisting in acquisition of temperature/distortion curves of heated sample of sand mould material and correlation with curves of their dilatation and also the inverse solution method are signalized as new proposition to estimate the chosen mechanical moulds parameters.