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Modeling of feeding of grey iron castings

Perzyk M., Gontarski T.

Archives of Foundry Engineering

2011

Vol. 11, iss. 4

187-193

The aim of the paper was development and testing a new methodology for adjusting of simulation parameters of casting processes. Instead using production castings with limited shapes, the methodology utilizes especially designed virtual castings of arbitrary geometries, with rigging systems calculated according generally approved principles, based on industrial experience. The present work tests included risers for grey iron castings, designed according Karsay's recommendations; the simulations were made using the commercial software NovaFlow&Solid. The preliminary simulations have shown that the parameters, which are most important from the viewpoint of occurrence of the shrinkage defects, are the density change during solidification and the gravity influence. Further systematic simulations allowed to find that the feeding flow modeled in the computer program does fully correspond to those practical recommendations: the flow is too easy in vertical direction an to difficult in horizontal direction. Despite that, it was possible to formulate recommendations regarding settings of the above simulation parameters which would facilitate correct predictions of the shrinkage defects in grey iron castings: the influence of gravity should be 'high' and the density change between liquidus and solidus temperatures should be between 0 to 78 kg/m3, depending on the feeding distance.