Modelling, simulation, and optimization of casting processes

Modelling and optimization are crucial tools during the design phase to ensure optimal design and function of the product. RISE has extensive experience of modelling, simulation, and optimization of casting processes.

Why simulation of casting processes?

Casting simulations are primarily used for optimizing the casting configuration with respect to mould filling and solidification with the aim of minimizing defects typically occurring during the casting process ensuring thus time- and cost-effective product development.

The model, or the theoretical calculations, are based on a mathematical model of the physical processes resulting in a set of differential governing equations which are solved by appropriate numerical methods. These range from fluid flow problem during the mould filling to heat-conduction during the solidification phase, as well as the solid mechanics of the solidified body. These are then utilized for detailed analysis of the complete process ensuring an optimal design of product. These numerical studies are most often conducted using commercial codes specifically designed for each task containing necessary data such as material-data of the alloy and the mould. It also helps the casting company determining the most appropriate casting design parameter configurations. By optimization of the gating system regarding the type, size, and location, it is possible to gain deeper insight into quantities which are usually not know beforehand, e.g., velocities, permeability of the mould and how these could affect defects such as porosities and shrinkage.

Services offered:

Topology optimization, FEA & Heat-transfer & Thermomechanical analysis.
Casting simulations
Cast ability analysis & process optimization, CAD-CAM-CAE support