Simulation of processes where a model made of polystyrene or similar material is used, which vaporizes when molten metal is poured into the mold, allowing for complex and detailed shapes in the final casting.
PoligonSoft enables the detection of potential defects during the early phases of the technological process design and develops an efficient methodology, in addition to reducing the number of necessary tests and speeding up the introduction of casting into the production cycle.
Filling Dynamics
Macro and Microporosity
Residual Stresses
Cracks (Hot and Cold)
Deformations and Warping
Hydrostatic Pressure
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Save significant costs in materials and labor, in addition to reducing product development time.
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Prevent and correct casting defects, such as porosity, air inclusions, or solidification issues.
Experiment with different variables of the casting process to find the most efficient configuration.
High-strength cast iron - VCH50
Mold - Quartz sand 1K1O2O3
Mold temperature - 20°C
Pouring temperature - 1500°C
Sprue diameter - 48 mm
Filling time ≈ 30 seconds
Molding box size in clear - 1500x1500
The company provided a model of the piece and the proposed casting process to check for the possibility of defects.
Velocity fields of the melt during the filling process
Temperature fields of the melt during the filling process
Locations of hot spot formation during solidification
Temperature fields of the melt during solidification
As a result of the simulation, it was determined that it is not possible to obtain a quality piece using the proposed technology.
The porosity can reach 100% due to the absence of feeders at the locations of hot spot formation on the flanges.
To correct the problem, significant mold correction is required, with the addition of feeders in the problem areas, as well as the elimination of holes in the flanges, which apparently were included in the model due to an error.
The main task in the manufacturing of small batches of castings is their rapid production with minimal cost in technological development and preparation for production. This challenge was to be addressed in the development process of the 'Gearbox' casting, made of 35L steel, using the lost foam casting technology.
Control operations after the manufacturing of the first casting revealed shrinkage cavities and porosity in the areas of contact with the gearbox cover. After this, it was decided to abandon real experiments and determine the causes of defects using the PoligonSoft computer modeling system for casting processes.
The company was provided with a temporary license for this software, and all the work to modify the technology was carried out independently by the foundry workshop specialists.
Porosity Distribution in the Casting
Modeling and analysis of the technology showed that, with the existing design, solidification is inevitably associated with the appearance of problems.
As a result of the research, a new design of the casting block was developed, which ensured the absence of defects in the contact areas between the cover and the body. The dimensions and location of the feeders were determined through a series of numerical experiments, without the need to modify the model equipment or to manufacture experimental batches of castings.
When modeling in 'PoligonSoft' showed the desired pattern of shrinkage with the modified design of the casting block, an experimental batch of castings was manufactured, followed by their mechanical processing and defect control. The results obtained allowed the new technology to be implemented in production. The order was completed on time and with minimal costs, and the company obtained the expected profit.
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