Metal Casting Zone Info Blog

Posts Tagged ‘Simulation’

This simulation was performed at Alloy Casting Industries in New Hamburg, Ontario Canada. The casting is a 200 lb. alloy steel impeller. For more information call Alloy Casting Industries at 519-662-3111 or visit us on the web at www.alloycasting.com

As a matter of comparison; here is a modelled “textbook” AFS 1-4-4 fill system. The temperature colour gradient = Top:1600C Bottom:1550C Alloy: 1026 Carbon Steel DO NOT USE THESE ANTIQUATED, ARBITRARY METAL DELIVERY SYSTEMS. THEY ARE INADEQUATE AND CANNOT PRODUCE WORLD-CLASS CASTINGS.

A simulation comparing the assigned feeder parameters per Table 2. design 16 of the paper entitled “Tapered Riser Design Optimization” by Creese/ Xia Plate casting moduls = 2 in. (plate thickness/2) Plate casting volume = 1024 in3 Cylindrical feeder volume = 679 in3 Tapered feeder volume = 525 in3 The simulations were performed using an 18Cr-8Ni stainless steel in resin bonded sand molds. I have run several simulations using the design parameters per table 2 (all with stainless steel) and have found that in all situations the tapered top feeder performed inadequately.

The waterfall action of the metal entering each cavity is a nightmare and needs to be eliminated. You are certain to find that the first “dribbles” of metal entering the cavity will end up as an “inclusion” in the casting. In all situations it is important to prevent the metal from free-falling.

This simulation was performed at Alloy Casting Industries in New Hamburg, Ontario Canada. An observation of thermal flow channel evolution during the delivery of molten metal to the mold cavity.