What Is Sand Casting Simulation Software?
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| Sand Casting Simulation Software |
Sand casting simulation software is used in the metal casting industry to simulate the sand casting that is to be produced using the sand casting process before they are actually manufactured on the shop floor simulating actual conditions to produce defect-free high-quality casting.
Analysis of the sand mould, material, molten metal, pouring temperature, strength of the mould, solidification of metal in the sand mould material, pattern, pattern material and drawing the casting out of the casting is simulated using this software.
This software increases the optimization of the castings, increases the trust in the foundry, supplier and customers and increases the profits and confidence in manufacturing complex sand casting.
Software used for sand casting simulation software can also be used for lost form simulation software.
I have written a list of the sand casting/moulding simulation software below.
List of Investment Casting Simulation Software
Following is the software used in the foundry to do the analysis of the sand casting.
- MagmaSoft
- NovaCast
- Flow-3D
- AnyCasting
- TherCast By TransvalorAmericas
Sand Casting Simulation Software Analysis
The following analysis can be carried out using sand-casting simulation software:
- Sand casting simulation software analyses the sand mould, sand mould material, cavity made from a pattern, sand casting tools, vents and moulding structure.
- This software is used to study and analyse the flow of molten metal in the mould cavity, the velocity of metal, solidification near the core, the high pressure of molten metal that can damage the cavity, low velocity and volume of liquid metal that will cause premature solidification of casting sections.
- This software analyses the solidification rate, premature solidification, delayed solidification, incomplete fusing of casting, incomplete solidification at the core surface, metal penetration in the sand mould, deformation during cooling, hotspots, cracks and swelling during the casting process.
- The software will study the surface finish, dimensional accuracy, part tolerances, geometry, shape, size, texture and complex casting sections.
- Study of the volume of molten metal, yield, incomplete poured shot, excess metal in the gating system and volume gaps in the gating system.
- The location of the riser, number of risers, exothermal material for the riser, type of riser and shape of the riser can be decided by the software.
- Position of the sprue, location, sprue diameter, sprue shape, size, sprue opening and flow rate of molten metal in the sprue.
- Temperature distribution, heat loss and heat gradient analysis from the molten metal to the mould cavity, core, mould wall, inserts, and gating system specifically the riser.
- Sand core location, types of core, dimension, interruption of molten metal with core, core size, core shape, core cracking and deformation during the metal solidification process.
- Study of casting defects like blowholes, hotspots, hot tears, cracks, sand holes, deformation, inclusions, misrun, cold shut, scabs and internal air pockets/cavities.
Sand Casting Simulation Software Application
Following are the sand casting products, parts and mechanical components that are simulated using the sand casting simulation software:
- Large heat exchange pipes.
- Sculptures, figures and art pieces
- Large casting blocks to produce die metal mould.
- Cylinder heads.
- Large nuts, gears, pulleys and bolts.
- Fixtures, housing, cover and cases
- Conveyors rollers and rail brackets.
- Agriculture machine parts such as plough and hopper.
- Stand base and table of shaper and planner machine.
- Counterweight and table stand.