Original Date: 11/03/1996
Revision Date: 01/18/2007
Information : Casting Simulation
Oak Ridge National Laboratory (ORNL) has established a casting simulation facility and an integrated approach to manufacturing cast components. This approach combines manufacturing experience with modeling technology in a way that streamlines the manufacturing of a cast product. Oak Ridge National Laboratory’s (ORNL’s) cutting-edge technology also provides strong technical support and manufacturing experience to support the entire process from product concept to production.
The integration of various CAD and design tools provide ORNL with the flexibility to efficiently design the part and simulate the casting process. ORNL combines its simulation environment, ProCAST, with various design software models such as PATRAN, IDEAS, IFEM, GFEM, ProEngineer, ANSYS, ARIES, and ANVIL. Using its manufacturing and modeling technologies, ORNL provides simulation analysis capabilities involving solidification through conjugate heat transfer, micromodeling, residual stress, radiation heat transfer, electromagnetic effects, and buoyant particle tracking.
Typically, ORNL electronically processes the part definition of a casting to create an analysis model. Casting- simulation studies then determine the most effective boundary conditions for ensuring optimum molten metal flow, proper filling of the mold, and solidification of the cast product. This method usually reduces segregation and radiographic results to an acceptable level. Quite often, the simulation creates a new design or prototype, or finds a near-net or net shape cast product to replace a wrought product. By using an integrated manufacturing approach, ORNL produces high-quality, sound castings.
ORNL’s unique technology and capabilities guide the design of the part and the casting process from concept to final product. Costly trial-and-error casting runs are eliminated by simulating the process and optimizing the design features, prior to an actual casting run. Potentially reducing costs by up to 50%, ORNL has realized benefits in cost reductions, cycle-time reductions, and material-waste reductions.
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