- #Can magmasoft simulation lost foam casting software
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Increasing the instability of the melt tip interface adversely affects product quality. The gas pressure in the kinetic zone has a significant role in preventing the sand collapse in contact with the kinetic zone and in reducing the instability of the interface at the tip of the melt. In lost-foam casting, an expanded polystyrene pattern is vaporized by the heat of the advancing metal melt, forming a gas gap in front of the metal tip. If the residual foam pyrolysis is not completely discharged and the pressure balance in the mold is altered during the pouring operation, the sand may collapse, resulting in casting defects. Many studies have been conducted to identify and solve the causes of casting defects. However, the lost-foam castings are susceptible to the generation of various defect forms. Furthermore, no harmful gas is produced from the core. Moreover, the use of dry sand without coking force and a resin-containing core reduces the manufacturing and waste treatment costs. The lost-foam casting process has several advantages which allow the casting of complex shapes because the molten metal is poured without removing the pattern. Finally, the molten metal is poured, and the melt is replaced with the space occupied by the solid foam pattern, resulting in the desired cast products. The first step is making the pattern of the desired shape, which molds the expanded polystyrene beads, and the foam pattern is placed in a sand flask, and unbonded sand is poured around the pattern and compacted by vibration. In the last three decades, lost-foam casting process (LFC) has been widely adopted to manufacture complex parts without the need for a core. The results obtained from the preliminary sand experiment and the actual casting experiment validated the equation. In the actual casting experiment, pressure of the kinetic zone in front of the metal tip was directly measured. An actual casting experiment was conducted by melting nodular cast iron to verify this equation. The void ratio of the sand effect on the minimum gas pressure was included in the equation. A new mathematical equation was proposed from the results of the preliminary sand experiment. In this preliminary sand experiment, compressed air was used instead of gas in the kinetic zone. A preliminary sand experiment was conducted to predict the gas pressure and reduce the number of actual casting experiments. Successful computer simulations can help reduce the number of trials and the lead time while designing new casting products. When the minimum gas pressure can be predicted, computer simulation becomes possible. Therefore, the minimum gas pressure for preventing sand collapse is required. The extremely high pressure causes many problems, such as reducing the melt velocity and inclusion of residual decomposition of the pattern in the castings, and very low pressure causes sand collapse.
#Can magmasoft simulation lost foam casting software
If you want to add your company, or specify informations, please contact the Blogmaster (with commercial software and Website link). We don't compile pure academic codes.Pressure of the kinetic zone is an essential factor for making defect-free castings in lost-foam casting process. This list is not exhaustive, and things move fast enough. STAR-CD - Siemens (internal combustion engine-bloc)įind all the articles on foundry process simulation posted on this blog.Internal combustion engine, crash simulation. International journal of modeling and simulation, and scientific computing., trade fairs dedicated to simulation process softwares
#Can magmasoft simulation lost foam casting free
Heat transfer, free surface, monophase or multiphase, particle flows, fluids interactions, combustion, multi-physics Microstructural evolution, material properties, material database, thermodynamics and phase diagram calculations, .ĬFD (Computational Fluid Dynamics) softwares
Microstructural and phase diagram simulation SOLIDcast, FLOWcast and OPTIcast - Finite Solution.Sand casting, high pressure die casting, gravity die casting, investment casting.
#Can magmasoft simulation lost foam casting plus
) plus CFD multiphysics codes and also Websites dedicated to process simulation. We have listed the main softwares used in various industries (hot forging, plastic injection moulding, metal casting, additive manufacturing, welding, cold forming process. Numerical simulation of manufacturing process is playing an increasingly important role in companies strategy.