Simulation And Processing Optimization Of Large Steel Castings

Casting a complicate materials forming process with typical nature of kinetics. After a long time of experience accumulation and knowledge based development, computer-based virtue reality has been successfully developed that is capable of visualize the previously invisible process to lay a sound base for process optimal design to eliminate the potential risks of production of large-scale steel castings. Therefore, since it was commercial available, the computer aided virtue reality has become an powerful and important methodology that drives the casting design change from experience base practice into a technology that capable of offering optimal design based on processing science and knowledge.In practice, the micro- and macro-structure of a casting forms during casting process. The formation of processing defects, such as shrinkage voids, porosity, deformation, hot-cracking, etc., are closely related to the invisible transfer phenomena and the solidification behavior of melt in the casting mould cavity. Therefore, visualization of the above with the aid of numerical simulation software become the main challenge and task of a foundry engineer and, of course, the main focus of the present stud.With the aid of MAGMASOFT, a well-known casting simulation software, the present study concentrates on the virtual reality of melt flow during cavity filling, heat exchange post filling, solidification behavior of the melt, and the formation of different processing defects during production process of large steel castings, such as turbine blade, valve body, etc., to obtain optimal processing design. The emphasis of the simulation is focused on the relationship of extend of porosity and the taper between riser and casting in order to maximize the casting profile without risking the processing quality and the yielding ratio.