Methodology of Comparative Validation of Selected Foundry Simulation Codes

Abstract

The validation of each simulation code used in foundry domain requires individual approach due to its specificity. This validation can by elaborated on the basis of experimental results or in particular cases by comparison the simulation results from different codes. The article concerns the influence of grey cast iron density curve and different forms of solid fraction curve Fs=f(T) on the formation of shrinkage discontinuities. Solid fraction curves applying Newtonian Thermal Analysis (NTA) were estimated. The experimental and numerical simulation tests were performed on the castings, which were made with Derivative Thermal Analysis (DerTA) standard cups. The numerical tests were realized using NovaFlow&Solid (NF&S), ProCast and Vulcan codes. In this work, the coupled influence of both curves on the dynamics of the shrinkage-expansion phenomena and on shrinkage defects prognosis in grey cast iron castings has been revealed. The final evaluation of the simulation systems usefulness should be based on validation experiment, preceded by comparing the simulation results of available systems which are proposed in given technology.

Keywords

• Solidification process
• Castings defects
• Simulation codes
• Cast iron
• Macro/micro models