Tips & Tricks

Why is it important to have coupled stress calculations?

Casting process issues related to hot tearing and cracking of the casting, thermal fatigue of dies and prediction of the final shape of a part are a challenge for foundries. Powerful, multi-physics simulation tools are now available to address them. This e-tip will consider the advantages of a fully coupled thermal, fluid flow and stress analysis of casting, in particular in view of the above mentioned challenges.

Thermomechanical modelling of continuous casting

Two application examples are showing new possibilities to take into account stress and deformation by the simulation of continuous casting processes. The variability of the presented examples prove that the proposed method is not limited to a certain class of applications, dimension and alloy composition. Since the gap formation can now be taken into account, the results are expected to be much more precise. This approach opens a wide field of application in order to better understand and control the heat transport in continuous casting processes.

Modeling the solidification of cast irons

Successfully modeling solidification of Cast Iron is of great help for the foundries to reduce their production costs and thus to increase their profits. If the basic physical solidification phenomena are correctly modeled by the simulation tools mold risering can really be optimized.

Why it is useful to describe problems in terms of non-dimensional parameters and which ones are the main important in solidification?

A dimensionless quantity is a quantity without any physical units. Such a number is typically defi ned as a product or ratio of quantities which do have units, in such a way that all units cancel. Dimensionless quantities are widely used in the fields of physics and engineering but also in every day life.

Influences of Solidification Length and Pressure Intensification on Gas Shrinkage Microporosity in Casting Components

Porosity in castings is a major defect since it affects the mechanical properties. In particular porosities are sites for the initiation of fatigue cracks. Therefore, the reduction of porosity fraction and size, the control of porosity distribution and morphology are crucial for the optimization of mechanical resistance of as cast components.