Casting simulations

CIREX’s knowledge in the area of casting simulations guarantees a stable process. Determining the proper casting configuration during production is a relatively complex process and the results are not always known beforehand. The casting process therefore needs to be simulated with a computer program. A casting simulation is a 3D model, which simulates the entire casting process. CIREX has used the same simulation software for many years and has built up considerable practical experience and knowledge. Casting simulations provide a high degree of process certainty, prevent technical problems and ensure that a project does not encounter delays.

Important parameters during casting simulations include:

  • Design of the gating system
  • The choice of steel alloy
  • Air permeability in the ceramic mould
  • Temperature during casting
  • The product’s coagulation behaviour

3D CASTING SIMULATION PREVENTS EXPENSIVE PROTOTYPING

As CIREX has the software for performing casting simulations, we can make a significant contribution to the ultimate design and, with this, to the quality of the cast piece. We estimate that more than 90% of the errors in casting usually occur due to design errors and that only 10% are actually attributable to production problems. Many design errors can be observed on time using simulation software. After this, the design or the process parameters can be adapted. This ensures that no problems arise during the production of the casting.

The high cost of faulty casts is also prevented. Prototypes used to be made to detect errors; now this is done using 3D casting simulation. The so-called ’trial-and-error’ procedure is now history. The casting process and the cast piece can be optimised well using simulation software. It improves quality and reduces production costs considerably.

INVOLVE CIREX EARLY IN THE DESIGN PROCESs

If our engineers are involved early in the design process, our specific knowledge of casting and solidification simulations is of great benefit to you. Thanks to Early Supplier Involvement (ESI), you are assured of an optimal casting. Therefore, when tendering for the casting, do not simply choose the lowest bidder, but evaluate the quality offered.

Benefits Of Casting Simulations

  • Predicting turbulence or laminar flow of the liquid steel during casting
  • Detecting possible inclusions
  • Predicting solidification (behaviour & time)
  • Predicting tensile forces and deformations during the cooling of the cast piece
  • Improved product quality
  • Robust casting process
  • Less re-smelting, reduction of scrap
  • Shorter production times
  • Indicating areas in the cast piece that might have porosities and/or the formation of cracks