COMPUTER AIDED DESIGN OF CASTING

INTRODUCTION
Compared to the history of metal casting, the use of computers for casting is
nascent, spanning less than three decades. Being a knowledge intensive process, metal
casting stands to benefit greatly from the development and deployment of tailor-made
software tools. The paper describes the evolution of software tools for casting design,
broadly segregated into three phases spanning the decades 1980s (basic CAD), 1990s
(desktop simulation) and 2000s (intelligent design). While computer-aided design and
simulation software can greatly enhance productivity, quality assurance and casting yield,
their penetration in small/medium foundries and engineering companies has been poor. The
latest software tools combine heuristic knowledge, geometric reasoning and information
management. They essentially behave like electronic assistants - performing the tasks
automatically, while allowing the user ultimate control over decisions. The paper presents
such an intelligent assistant for casting engineers (AutoCAST) and describes how it assists
in designing, modeling, simulating, analyzing and improving cast products over electronic
networks - providing a glimpse of the way castings will be designed in future.

COMPUTER-AIDED CASTING DESIGN

The main input is the 3D CAD model of an as-cast part (without drilled holes, and
with draft, shrinkage and machining allowance). The model file can be obtained from the
CAD, Solid works etc softwares. Various display options such as pan, zoom, rotate,
transparency, and measure are provided to view and understand the part model. The cast
metal and process are selected from a database. Part thickness distribution is displayed for
verifying the model and evaluating part-process compatibility.
 The cast metal and process are selected from a database. Part thickness distribution
is displayed for verifying the model and evaluating part-process compatibility.

The methods design involves cores, feeders and gating system. Holes in the part
model are automatically identified for core design. Even intricate holes can be identified by
specifying their openings. The print length is computed based on the core diameter and
length (the user can change these if required), and the entire core model is automatically
created. The program suggests the number of cavities depending on the mold size
(selected from a foundry-specific library), considering both cavity-cavity and cavity-wall
gaps. Then the part model is automatically duplicated in the correct locations as per the
desired cavity layout.
 To facilitate feeder location, the program carries out a quick solidification analysis
and identifies feeding zones. The user selects a suitable location close the largest feeding
zone, and the program automatically computes the dimensions of the feeder using modulus
principle (solidification time of feeder slightly more than that of the feeding zone). The feeder
model is automatically created; the user can change its dimensions or apply feed aids such
as insulating sleeves and exothermic covers. More feeders can be created by specifying
their positions. The gating channels are created semi-automatically. First, the user indicates
gate positions on the part or feeder model. Then the sprue position is decided, and it is
connected to the gates through runners. Runner extensions are automatically created. Any
type of gating system: horizontal, vertical, investment tree, and direct pouring can be
created or modified within minutes. The program also suggests a suitable filling time (which
can be changed by the user), accordingly computes the dimensions of the gating channels,
and creates their solid model.
AUTOMATIC OPTIMIZATION
The mold cavity layout, feeders, and gating are automatically optimized based on
quality requirements and other constraints. For mold cavity layout, the primary criterion is
the ratio of cast metal to mold material. A high ratio such as 1:2 (cavities too close to each
other) can reduce the heat transfer rate and lead to shrinkage porosity defects. A low ratio
such as 1:8 (cavities too far from each other) implies poor utilization of mold material and
reduced productivity. The program tries out various combinations of mold sizes and number
of cavities to find the combination that is closest to the desired value of metal to mold ratio.
The gating design is driven by the ideal mold filling time, which depends on the cast metal,
casting weight and minimum wall thickness. Fast filling leads to turbulence-related defects
(such as mold erosion, air aspiration and inclusions). On the other hand, slow filling may
cause defects related to premature solidification (such as cold shuts and misruns). To
optimize the gating design, the program simulates the mold filling and computes the total fill
time. A simplified layer-by-layer algorithm is used, taking into account the instantaneous
velocity through the gates (considering back pressure, if applicable), and the local cross-
section of the mold cavity. This gives an accurate estimation of filling time, while being
computationally efficient. If the difference between the ideal and simulated filling time is
more than a specified limit, the program automatically changes the gating design, creates its
solid model, and verifies the filling by simulation.

The feeder optimization is driven by casting quality, defined as the percentage of

casting volume free from shrinkage porosity. The user indicates a target quality. The
program automatically changes the feeder dimensions, creates its solid model, carries out
solidification simulation, and estimates the casting quality. The solidification simulation
employs the Vector Element Method, which computes the temperature gradients (feed
metal paths) inside the casting, and follows them in reverse to identify the location and
extent of shrinkage porosity. This has been found to be much faster than Finite Element
Method, without compromising the accuracy of results. The feeder design iterations are
carried out until the desired quality is achieved, or the number of iterations exceeding a set
limit. The user can accept the results, or reject them and modify the feeder design
interactively.

Today AutoCAST is the most widely used casting software in India (foundries,
engineering and R&D institutes, and consultants) covering all major cast metals and
processes. Many others have used the software for benchmarking. Simulation consultants
are available across the country to provide local technical support, ensuring a smooth
transition to computer‐aided methoding.
AutoCAST – The Intelligent Assistant
The casting design system was developed based on a detailed study of the industry status,
followed by proposing a conceptual system, obtaining feedback from potential users and
incorporating their suggestions. The Foundry Benchmarking Survey conducted in 1995-96
by American Metal casting Consortium and sponsored by the Department of Defense
provided a clear picture of the industry status. The survey team was led by
Prof. R.C. Creese at the West Virginia University and the author was a consultant for
analyzing the survey data. The study showed that the average lead time for the first article
of approval is about 10 weeks for aluminum and steel foundries, 11 weeks for ductile iron
and 14 weeks for gray iron foundries. Among various factors studied, tooling development
emerged as the most important one, taking up as much as 80% of the total lead time. This
showed that significant savings in overall lead time could be achieved by compressing the
tooling development time alone, including the time for its design, manufacture and shop
floor trials. For this purpose, close cooperation is necessary between all engineers involved
in a casting project.
Accordingly, the conceptual design of a computer-aided concurrent engineering
system was developed and described in a web site called Casting 2000 which was hosted
by the Concurrent Engineering Research Center in Morgantown, West Virginia during 1996-
97. It described a suite of intelligent software tools for assisting and linking casting life-cycle
engineers (product designers, tool makers, foundry engineers and supply managers) for
better and faster decision making (Fig.4). The web site received encouraging
feedback from all parts of the world, and the suggestions helped in designing the
information backbone of the software. A prototype of the system, called AutoCAST, was
developed and shown to casting engineers. Their suggestions were incorporated to improve
it further in terms of features, programs, database structure and user interface
CASTING DESIGN PROGRAMS
AutoCAST comprises a suite of nine programs to perform various tasks associated with
casting design. Each program comprises a set of modules for design, solid modeling,
simulation, analysis and improvement. The programs are:
Product Design: This program helps in importing a solid model of the part from an external
solid modeler through a standard exchange format, followed by computation of geometric
properties. Wall thickness, section variation, complexity, holes and other criteria are used
for castability analysis, followed by suggestions for design improvement.
Parting Design: This program suggests the best orientation of the casting in the mold,
generates several parting lines and determines the best alternative, aligns the parting line
with the mold parting plane, and finally analyzes the current parting in terms of flatness,
draw distance, draft volume, dimensional stability, etc. to suggest improvements.
Core Design: This program first identifies cored features in the part model: through holes,
deep pockets and undercuts. For each cored feature, it designs the core print and creates a
solid model of the entire core. Finally, it analyzes the cored feature for failure, venting and
other criteria, based on which guidelines for design improvement are presented.
Mold Design: This program selects the most appropriate mold box to enclose the casting,
determines the optimal number of cavities and displays the cavity layout. The mold design is
analyzed in terms of metal to sand ratio, cavity shape and other criteria, based on which
guidelines for design improvement are displayed.
Rapid Tooling: This program suggests an appropriate route for producing master pattern,
master mold, regular pattern, regular mold, master core, core box and regular core using a
sequence of rapid prototyping, rapid tooling and conventional methods. It also suggests the
best orientation for minimizing the fabrication time using the above techniques.
Feeding Design: This program first simulates the solidification of the casting to determine
the location of hot spots and suggests an appropriate location for the feeder. It also
calculates the feeder dimensions, creates its solid model and attaches it to the casting.
Feeding aids such as chills, insulating sleeves and exothermic covers can be modeled. The
feeding design is further verified by progressive solidification plots on a section and
directional solidification vectors (feed metal flow paths) inside the casting. Yield,
feeding efficiency and ease of fettling are computed to compare different layouts.
Gating Design: This program suggests the connection points for ingates and the location of
sprue, followed by the layout of runners. It determines the optimal pouring time, designs the
entire gating system and creates its solid model. Mold filling simulation is performed to
determine the actual filling time, and to identify gating related defects. The gating design is
analyzed in terms of yield, ease of fettling and other criteria based on which suggestions for
design improvement are presented.
Process Planning: This program suggests an appropriate casting process for producing
the part (given its metal, weight, lot size, quality specifications, etc.). It plans the
requirement of cast metal, mold sand, core sand and other materials. An activity based
approach is used for analyzing the lead time and costs for producing the casting.
Quality Assurance: This program helps in casting inspection in two ways. It assists in
setting up reference dimensions between specified locations on the casting surface and
determines the ideal distance between them. It also simulates radiography to produce the
radiograph of a defect-free casting, which can be compared with actual radiographs to
identify internal defects in the casting.
CONCLUSIONS
Computer-aided casting design has come a long way since the early programs of 1980s
and has proved its benefits in terms of enhanced productivity, quality assurance and
improved casting yield. Most castingdesign/simulation programs usually pay back for
themselves within an year. However, the software has tobe comprehensive and user-
friendly for widespread penetration, specially in small/medium foundries and engineering
companies. The paper showed how an intelligent software can automate casting design,
modeling, simulation, analysis and suggestions for improvement while allowing the user
ultimate control over all decisions. While it is of great use to casting engineers in better and
faster decision-making, greater benefits will be achieved by analyzing cast products at the
design stage itself and preventing potential problems through suitable changes to part
features. In addition, product engineers, tool makers and casting engineers will be able to
share relevant information with each other over electronic networks, thereby avoiding
confusion and errors and significantly reducing the non-productive time for completing a
casting project.
REFERENCES
1. B. Ravi, “Casting Simulation and Optimisation: Benefits, Bottlenecks, and Best Practices,”
Indian Foundry Journal, 54(1), 47-52, 2008.
2. Ravi B, Metal Casting: Computer-Aided Design and Analysis, PHI, New Delhi, ISBN 81
203 2726 8, 4th print, 2008.
3. Advanced Reasoning Technologies, AutoCAST information and case studies,
http://www.autocast.co.in, 2008.
4. B. Ravi, “Bridging the Digital Divide in Casting Simulation Technology,” Indian Foundry
Journal, 55(4), 34-38, 2009.