RNariman MetalCasting Consulting, Inc'

1
RNariman Metal-Casting Consulting, Inc.
Example of simulation work.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
Simulation of casting solidification in a sand
mold using the FEM process modeling program
ProCast. First iteration using original geometry.
The adjacent macroporosity plot shows three
disctinct areas of shrinkage porosity in this
part.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
Based on the Simulation results, the Foundry
recommended the addition of two ribs to de
original design. The change was approved by the
customer.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
Model preparation for actual production run
simulation.
Part and Sand Mold Assembly
Rigged Part with risering system.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
ProCast Temperature-Time plot. Heat Flow is
directional towards the three risers. This a
desirable condition.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
Solid Fraction fringe plot sequence . The void
zones indicate solid metal. The Yellow zone is
liquid metal at the solidification temperature.
Isolated yellow spots unattached to risers would
be an indication of porosity.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
Macroporosity plot. All porosity is contained in
the three risers. The risers will be removed,
leaving a sound castings.
Porosity found in the original simulation has
been eliminated.
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High Alloy Foundry. Interactive Casting
Engineering via CAD Model Transfer.
Sectioned sample casting. No evidence of macro
or micro porosity after dye penetrant inspection
of the cut surfaces. No integrity problems were
found in X-Ray as well.
Porosity found in the original simulation has
been eliminated.