Casting simulation has become a powerful tool to visualize mould filling, solidification and cooling, and to predict the location of internal defects such as shrinkage porosity, sand inclusions, and cold shuts. It can be used for troubleshooting existing castings, and
for developing new castings without shop-floor trials. This paper describes the benefits of casting simulation (both tangible and intangible), bottlenecks (technical and resource related), and some best practices to overcome the bottlenecks.
These are based on an annual survey of computer applications in foundries carried out during 2001-2006, which received feedback from about 150 casting engineers, and detailed discussions involving visits to over 100 foundries. While new developments such as automatic optimization of method design are coming up, a national initiative must ensure that the technology is available to even small and medium foundries in remote areas.
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