How Do Simulations Improve Heat Distribution During Solidification in Sand Casting

How Do Simulations Improve Heat Distribution During Solidification in Sand Casting


Cast product rejections due to casting defects would certainly rank among the worst nightmares of sand casting engineers, and they are of vital importance for casting quality.

In today’s competitive marketplace, the modern metal forming industry has taken full advantage of the advanced techniques available. Solidification modelling illustrates a phase change phenomenon that is both incredibly complicated and very important in many fields of engineering and manufacturing. It also plays a critical role in automotive and aerospace applications.

Sand Casting Defects and Quality Issues

During sand casting process, when the molten metal is poured into a mold cavity, it solidifies and releases heat into the mold cavity. As the metal shrinks, an air gap is created between the cast and the mold. An air gap can obstruct heat flow from a cast to a mold, and is, therefore, one of the moving boundary conditions to be considered when running a casting simulation. Various parameters contribute to the quality of the casting during the simulation of a solidification process.

Sub-standard products with sand casting defects and quality issues have always been a major concern in the casting industry. Defects lead to poor quality of cast products, production delays, financial losses, etc. These issues can be avoided if casting designs are properly tested and optimised prior to mold production.

For those not familiar with the cutting-edge technology in metal casting, predicting casting defects may sound far-fetched.

The traditional method used by casting engineers to calculate aluminium solidification rates, shrinkage, and how much material is needed relies heavily on tacit knowledge. A prototype and parameter refinement process had to be iterated to test these calculations, a process that could be quite time-consuming and expensive. 

Importance of Casting Simulation Software

However, in recent years advanced simulation software is giving the casting industry a competitive edge. Using casting simulation software has enabled us to predict potential issues in sand casting, particularly in the metal solidification stage when defects are most likely to appear on the casting pieces.

It is difficult to model, simulate, and analyze the solidification process without the use of specialized software such as Moldflow and ANSYS

By using casting simulation software, engineers can see how their designs cast in real life, which can reduce prototype testing requirements and allow engineers to study and map the heat flow within the substrate and form the metal to the mold, and simulate the solidification process in progression. This enables visualization and mapping of the different heating zones within the casting that affect product quality.

With the advent of this software, the industrial sector is now using it to reduce development time and cost, and improve the durability and integrity of casting components, elements that are of utmost importance to customers. By streamlining the development process and reducing scrap and waste, also benefits the environment.


To summarize:

  1. Casting simulation is a form of transient thermal analysis, performed using a highly specialized software package.
  2. The simulation models heat distribution during the solidification process.
  3. Heat distribution inside the mold and casting piece is crucial for casting quality, and the mold temperature data from the simulation is useful in optimizing the operating parameters and gating design.
  4. Simulations can also help with improving casting quality, reducing the cost of development, and speeding up production optimization.

At Omnidex Castings, our engineers and technical experts operate at the forefront of technology and evaluate the latest developments in casting simulation software to see how we can further enhance our solidification, manufacturing processes and existing application development.

This approach is proving successful in reducing developmental costs, improving material utilization, minimizing casting defects, and streamlining our developmental phase.

Omnidex has a long-standing reputation for high-quality casting, we are always enhancing our operational capabilities through continuous investment in new technologies.

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Contact our Engineering Team to learn more about our diverse manufacturing and engineering service and how we can help on your projects.

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Omnidex is a World-Class Manufacturing and Engineering company that produces high quality, porosity-free casting products which are trusted by companies across different industries. Throughout the whole process, from product development to delivery, we strive to provide you with unwavering support. Providing you with unmatched diverse capabilities and experience, we help you overcome any obstacle.

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