This paper intends to validate the integrity and reliability of MAGMAsoft for the simulation ofmetal flow and solidification during the casting process. Various computational packages of CAD/CAE systems can be used to assist in mold design and prediction of castingquality ahead of mass production. Trial-and-error method to produce casting products from design to manufacturing is too costly and noteffective. This is due to the fact that sandcasting is economical and possesses the flexibility to produceĪBSTRACTThere is an increasing demand in manufacturing environment for the best quality of casting products at the right time and quantity.Foundries must be able to meet the just in time (JIT) requirement in order to survive in the competitive market and to achievecustomer satisfaction. Sand casting still accounts for the largest tonnage ofproduction of shaped castings. Sand casting is the casting process that has the longesthistory. Forexample, comparison of smoothed particle hydrodynamics (SPH)and MAGMAsoft simulations with experimental results for thewater analogue modeling of HPDC was reported by Paul Cleary,Joseph HA, Vladimir, Alguine and Thang Nguyen. The cast and mold design of theexperiment is transformed into a 3D model and imported intoMAGMAsoft to conduct the sand casting process simulation.Ĭertain validation of MAGMAsoft simulation for high pressuredie casting (HPDC) had been reported in literature. Thiswork intends to present a preliminary validation of MAGMAsoftcapability by comparing its simulation results with previousempirical thermal results of a sand casting mold carried out by aprevious researcher. Prior to applying the MAGMAsoft extensively to create sandcasting and die casting models for the simulation of molten metalflow (mold filling) and solidification (crystallization in the process ofcooling), it was suggested to carry out a validation plan to verifythe validity and integrity of MAGMAsoft simulation results. It is particularly helpful forfoundry applications to visualize and predict the casting results soas to provide guidelines for improving product as well as molddesign in order to achieve the desired casting qualities. INTRODUCTIONMAGMAsoft is a three dimensional solidification and fluid flowpackage developed to perform numerical simulation of moltenmetal flow and solidification phenomena in various castingprocesses, primarily die casting (gravity, low pressure and highpressure die casting) and sand casting. Shamsuddin Sulaiman, Lim Ying PioDepartment of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, 43400 UPM Serdang, Selangor VALIDATION OF MAGMASOFT SIMULATION OFTHE SAND CASTING PROCESS The earliestmethod of bonding sand grains to form a sand mold is by the use Theaverage grain size ranges from 220 to 250 microns. Other sands are also used for specialapplications where higher refractoriness, higher thermalconductivity or lower thermal expansion are needed.
Most sand molds and cores are made of silica sand for itsavailability and low cost. For conventional sand casting (lowtechnology sand casting), the maximum variability in dimensionfor a meter long casting is 0.13% corresponding to 1.25 mm.The probable variability of a good sand casting technique (hightechnology sand casting) for a meter long casting yields 0.04%corresponding to 0.40 mm, which is comparative toinvestment casting. This will enhance the capability ofsand casting to produce near-net-shape products and improveits competitiveness. However, advancedhigh technology sand casting process (improved sand quality andmold rigidity) enables this method to produce higher precisioncast products with better as-cast surface finishing that reducesthe cost of after-cast touch-up.
Ĭommon sand mold consists of top and bottom halves (copeand drag), and the number of cores may vary from none to adozen depending on the complexity of casting design.Conventional sand casting is not a precision process and requiresafter-cast machining processes and surface finishing to producethe required dimensions and surface quality. Cast materials capable of sandcasting are plain carbon, alloy and manganese steels, white andgrey irons, nodular iron, nickel and copper alloys, gunmetals,phosphor and aluminium bronzes, brasses, aluminium alloys andmagnesium alloys. 3/4, September/December 2004)Ĭastings of any material and the weight of castings can range fromtens of grams to hundreds of tons. 55Journal - The Institution of Engineers, Malaysia (Vol.