Implementation and Validation of Casting Simulation Methodology for Diagnostics of Lamellar Graphite Iron

This paper describes and validates a methodology for implementation of full-scale sand-casting simulation in a general-purpose finite element software, including mold filling, heat transport, solidification kinetics, chemical microsegregation and prediction of microstructure and material properties. The solidification model, customized for gray cast iron, includes novel methods for handling interaction between parallel dendritic and eutectic solidification modes and its impact of their interaction on the final microstructure. The validation involves a previously published gray iron casting experiment and involves comparison of simulated and experimental cooling curves, microstructure parameters and tensile strength. We believe that this is valuable to researchers and engineers seeking to improve the state of the art of casting simulation tools.

Automated summary

This paper presents and validates a methodology for implementing full-scale sand-casting simulation in a general-purpose finite element software, covering mold filling, heat transport, solidification kinetics, chemical microsegregation, and the prediction of microstructure and material properties. The customized solidification model for gray cast iron includes innovative methods to handle the interaction between parallel dendritic and eutectic solidification modes, and its impact on the final microstructure. The validation process involves comparing simulated and experimental cooling curves, microstructure parameters, and tensile strength using a previously published experiment on gray iron casting. This research is valuable for researchers and engineers aiming to enhance the capabilities of casting simulation tools.