Aluminum Casting Simulation & Solidification Analysis
Use Simulation to Improve the Casting Before Production
Aluminum castings can appear relatively simple on a drawing while presenting significant challenges during filling and solidification. Differences in wall thickness, geometry, gating, risering, pouring conditions and thermal behavior can all affect the final casting.
Cast Metals Technology uses casting simulation and solidification analysis as an engineering tool to better understand these conditions before and during the development of an aluminum casting process.
What Casting Simulation Can Help Evaluate
Simulation allows our engineering team to evaluate how molten aluminum is expected to behave as the mold fills and the casting solidifies. Depending on the project, analysis may help evaluate:
Simulation does not replace foundry experience or physical sampling. Instead, it provides additional information that can help our engineers make better-informed decisions during process development.
Mold filling characteristics
Solidification patterns
Hot spots and thermal concentrations
Potential shrinkage-prone areas
Gating and runner configurations
Riser size and placement
Pouring parameters
Changes in casting orientation
Effects of geometry and wall thickness
Evaluate Changes Before Modifying Tooling
When a casting presents a difficult filling or solidification challenge, making tooling changes through trial and error can be expensive and time-consuming. Simulation allows different approaches to be evaluated digitally before certain physical changes are made.
Gating Changes
Different gate, runner and feed configurations can be analyzed to understand how they may affect mold filling.
Riser Changes
Riser location and size can be evaluated in relation to the casting’s solidification pattern.
Casting Orientation
In some applications, changing the orientation of the casting within the mold can significantly affect filling and solidification.
Pouring Conditions
Pouring temperature and filling conditions can be evaluated as part of process development.
Part Geometry
Heavy sections, abrupt transitions and isolated areas of mass can be identified for additional engineering review.
An Iterative Engineering Process
Casting development is rarely about changing a single variable. Simulation is most valuable when combined with engineering experience, sampling and inspection.
3D Model → Initial Casting Design → Gating & Risering → Simulation → Engineering Review → Design Adjustment → Sample Casting → Inspection → Production Validation
If initial samples identify a problem, the information can be incorporated into another engineering and simulation cycle. This iterative approach helps CMT work toward a stable and repeatable production process.
Particularly Valuable for Challenging Castings
- Heavy and thin sections within the same casting
- Complex internal geometry
- Multiple cores
- Difficult feeding requirements
- Critical machined areas
- Historical shrinkage or porosity concerns
- New or significantly modified tooling
- Tooling transferred from another foundry
Simulation Combined With Aluminum Casting Experience
Simulation software is a tool – not a substitute for manufacturing knowledge.
CMT combines simulation results with practical experience in aluminum sand casting, tooling, coremaking, molding, pouring, finishing and machining. This allows simulation results to be considered in the context of the complete manufacturing process.
Our objective is not simply to produce a simulation. It is to use engineering analysis to help develop a more robust manufacturing process.
Learn more about our aluminum casting design and engineering support.
Frequently Asked Questions
What is aluminum casting simulation?
Casting simulation uses computer modeling to evaluate how molten aluminum is expected to fill a mold and solidify, helping engineers identify areas that may require additional attention.
Can simulation eliminate casting defects?
Simulation is an engineering tool that can help identify potential risks, but results still need to be combined with foundry experience, sampling, inspection and process validation.
Can CMT simulate an existing casting with quality problems?
Depending on the available design and process information, an existing component can be evaluated to better understand potential filling or solidification concerns.
Start With Your 3D Model
If you are developing a new aluminum casting, experiencing problems with an existing component, or transferring tooling from another foundry, CMT can review the application and determine whether casting simulation could be useful.