The foundry industry has been developed worldwide, a number of software that can assist the design work and various processes in the production of castings. Current usage of such software by metallurgical engineers is possible after a few days training, advanced computer knowledge is not required. Also, the simplicity, performance that can ensure the sales prices and that does not require powerful software equipment is the main advantages of these programs

Constantin BRATU

Ioan MARGINEAN

Sorin-Adrian COCOLAS

The Annals of “Dunarea de Jos” University of Galati Fascicle IX Metallurgy and Materials Science

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THE ANNALS OF “DUNAREA DE JOS” UNIVERSITY OF GALATI. 
FASCICLE IX. METALLURGY AND MATERIALS SCIENCE 
N0. 2 – 2009, ISSN 1453 – 083X 
 
 
 
 
SOFTWARE USED AT CASTINGS PRODUCTION  
 
Ioan MARGINEAN, Constantin BRATU, 
Sorin-Adrian COCOLAS  
Politehnica University of Bucuresti 
 
ABSTRACT 
 
The foundry industry has been developed worldwide, a number of software 
that can assist the design work and various processes in the production of castings. 
Current usage of such software by metallurgical engineers is possible after a few 
days training, advanced computer knowledge is not required. Also, the simplicity, 
performance that can ensure the sales prices and that does not require powerful 
software equipment is the main advantages of these programs.  
 
KEYWORDS: foundry industry, software, casting 
 
1. Software Foundry Industry 
 
It should be noted that these programs and 
computer in general, do not replace the "man" factor. 
Technology is thinking how to do technology. The 
used computer program supports the designer by 
making calculations for sizing and optimization are 
much more accurate and are obtained in a much 
smaller, making it possible to decide whether a design 
is correct or not. Using the soft prevents the execution 
of design errors that lead mostly to attainment of the 
required technical performance. 
These professional programs to simulate various 
phenomena occurring during flow and solidification 
of cast can be changed to simulate different methods 
of casting.  Mathematical models of these programs 
differ in principle by introducing additional 
conditions that arise due to their use in the 
solidification simulation for the various processes of 
casting. Simulation programs are generally intended 
for simulation of thermal fields in solidification of 
cast.  
Conditions to limit allowed by the software may 
be:  
 type Diriclet when considered as input data 
to the surface temperature of ingots or castings;  
 Neumann type when considering the input 
heat flux of the considered border segment, such as 
radiation or external sources of heat; 
 Cauchy type, it is considered as input data as 
well as the outside temperature coefficient of heat 
exchange between the global environment and system 
analysis.  
In general, the basic structure of the program, 
which was conceived and developed in a structure 
with multiple user options, distinguishes the following 
stages of work:  
 automatic mesh (the graphical) of castings in 
volume elements; 
 determining the type of coordinates used;  
 enter the number of areas of different 
materials;  
 introducing thermo-physical material 
characteristics for each area;  
 placing temperature of the mixture of 
hardware and training;  
 introduction of the surface temperature 
shrink head or mold;  
 introducing of time step and total time 
simulated;  
 the graphical representation of temperature 
and solidified areas.  
General use of software provides a convenient 
way of operating through a menu system which can 
call their main functions as handling input and output 
files; mesh domain analysis; enter the material; 
introduction of casting temperature and initial 
temperature; placing conditions on the surface heat 
exchange system analysis;  implementation of the 
program and other. 
 
2. Software Process for Simulation and 
Optimization of Solidification of Castings 
with Different Procedures  
 
2.1. NovaFlow & Solid CV Gravity 
NovaFlow & Solid CV is a complete mould 
filling and solidification simulation package based on 
advanced fluid flow and heat transfer theories. 
NovaFlow & Solid CV utilizes Control Volume 
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N0. 2 – 2009, ISSN 1453 – 083X 
 
 
Meshing technology (CVM). With this technology, 
the surface of the 3D model controls the shape of the 
mesh elements on the border of the casting. This 
creates cubic elements inside the casting and border 
cells on the boundary of the casting. This program 
simulates most of the casting methods on the market 
such as: gravity sand casting, gravity permanent 
mould, low pressure die casting, high pressure die 
casting, lost wax method, tilt pouring and lost foam 
process. All commercial alloys can be simulated such 
as: grey and ductile iron, steel, aluminum alloys, 
copper, zinc, magnesium-based alloys, super alloys 
and all types of mould and core materials that exist on 
the market and also exothermic materials as well as 
chills. Simulations visualize the consequences of a 
certain design of gating system and moulds. Casting 
defects such as oxide inclusions due to excessive 
turbulence, cold-shuts, shrinkage cavities and slag 
inclusions can be avoided by optimizing the design of 
the gating and venting system. 
 
 
Fig. 1. Print-screen of NovaFlow & Solid interface. 
 
2.2. SIMTEC/Wincast  
The program was developed by the company 
RWP (Germany) and uses the finite difference 
method (mesh is done automatically). It proposes a 
complete offer, from filling up efforts to determine 
the mechanical and thermal model using an elastic or 
elasto-plastic. In addition to modeling the processes 
that occur in the gravitational field are dealing with 
other processes (die casting, low pressure casting, 
“squeeze casting”, “loast foam”).  
 
Fig. 2. Screen capture of Simtec interface. 
 
2.3. Metal Master 
This program is expected to optimize the 
composition of cast irons under the conditions 
obtaining in the development of a minimum cost 
price, the achievement of numerous tests with various 
melt compositions: it does not require high 
performance computers and is very easy to use. 
 
2.4. ProCAST  
This program is developed by UES, USA and 
has a wide range of possible uses, grouped by 
modules. ProCAST has a way to determine enthalpy 
and solid fraction depending on temperature and alloy 
composition. It features a high performance mesh 
mode. The program integrates: a database of material 
characteristics, thermal analysis models, the flow and 
the efforts of components and metallurgical and 
specific models.  
 
Fig. 3. Low Pressure Casting. 
 
 
2.5. IronCAD 4.0  
It is a package CAD / CAM product company 
Desing Visionary Systems Inc. - USA and distributed 
in Romania by Metal Progress Soft. It’s designated 
geometric solids modeling and complex mechanical 
assemblies, molds, foundry molds, SDV's, electrical 
installations, and others. 
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N0. 2 – 2009, ISSN 1453 – 083X 
 
 
 
Fig. 4. IronCAD 4.0 program interface. 
 
2.6. Flow-3D  
The program was developed by Flow Science in 
the U.S. and specializes in the design flow. For 
application in the foundry to propose a list of models 
that allow even simulate hydraulic phenomena related 
to the development of special procedures such as 
filling the form for the process "lost foam", 
Thixocoulée ".  
Resolution is made by the method of control 
volumes.  
 
 
  
Fig. 5. Simulation flow and filling forms.  
 
2.7. MAGMA  
MAGMA is a German program, including flow 
and solidification, and modular design stays true to 
revolve around the control volume method. At the 
same time, the program includes the calculation 
efforts and deformations. It proposed a method of 
procedure "thixocoulée", which was developed in 
collaboration with the EFU. At the same time, models 
have been developed for determining segregation and 
mechanical characteristics, based on chemical 
composition and thermal evolution during 
solidification.  
 
Fig. 6. Magma casting design. 
 
2.8. ATASTM (Adaptive Thermal 
Analysis System)  
It is composed of system control and 
optimization of design for gray cast iron, malleable 
and nodular cast iron. The method was developed by 
NovaCast AB in collaboration with the Swedish 
Foundry Association and is based on the first 
derivative of the cooling curve combined with 
artificial intelligence applied. The system is a fully 
automatic registration of cooling curve from the time 
the iron is poured into the sample cup. After 
registration, the system looks at the curve; it calculate 
the derivative I and about 40 thermodynamic 
properties. A test result is usually given in 3-5 min.  
 
Fig. 7. ATASTM program interface. 
 
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2.9. NovaCast  
NOVACAST Program (Sweden) presented at 
the GIFA 1989 Congress solidification of alloys in 
simulated three-dimensional (3D) has incorporated an 
interface for downloading directly from AutoCAD 
drawings cast. The program analyzes the heat transfer 
finite difference method and can cause iso-solidus 
curves, field temperature alloy-form system, the 
biphasic and the fraction of solidified alloy and place 
of occurrence and size of areas where appears micro-
porosity. Currently, there are two modules: module 
solidification (NovaSolid) and module simulating 
cavity filling forms (NovaFlow).  
 
 
Fig. 8. System Design with NovaCast. 
 
Fig. 9. Modeling and simulation of high pressure 
die casting. 
 
2.10. CASTech  
The program simulates the filling and 
solidification of castings. Filling in Injection molding, 
currently proposed to be included in a future version 
of the program. Program CastDESIGN associated 
CastCAE version is used to calculate shrink head, 
which is to determine their size and location. The 
choice is made from a database, based on simulation 
results of solidification processes. 
 
Fig. 10. Porosity simulation with CASTTech 
 
Fig. 11. Modeling of a valve body casting. 
 
 
2.11. SIMULOR / PAM-CAST 
Simulation program developed by Silicon 
Graphics can simulate flow and solidification of 
alloys and is based on finite volume method. The 
method of calculation used is that of the control 
volumes. The program offers the following 
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FASCICLE IX. METALLURGY AND MATERIALS SCIENCE 
N0. 2 – 2009, ISSN 1453 – 083X 
 
 
advantages: the program is modular, allowing 
computing desired choice; CAO interface programs 
are taken into account in the thermal model, densener 
indoor, outdoor and air strips which are formed at the 
interface alloy-form; it makes a physical database for 
several aluminum-based alloys. 
 
Fig. 12. Specific solvers used at casting process. 
 
Fig. 13. High pressure die casting. 
 
2.12. AFSolid3D  
The program is conducted by the American 
Foundrymen Society and uses the finite difference 
method and can run on a PC. This program proposed 
by the foundry in 1986, claimed more than 300 
licenses worldwide. It has its own system and enables 
simulation training CAO shrink hole that occurs 
during solidification. It is possible, while shaping and 
filling the cavity, where casting gravitational field. 
 
2.13.SOLSTAR  
SOLSTAR company FONSECO program can 
calculate and divide the piece into a million parts by 
volume. Thus, multimillion version 3 can be 
calculated and share a song in 64 million volume 
elements and multimillion variant 2 than 3 million 
items in volume. Increased volume elements improve 
simulation accuracy in case hardening.  
The program presents facilities, such as easy to 
work with files, improved interface, an analysis of 
areas of developing micro-porosity. The program can 
be run only on powerful computers. 
 
3. Conclusion 
 
At current technical conditions such a design 
may be cast to ensure a controlled management of the 
process of solidification in industrial conditions. The 
usage of computer to study processes taking place 
during solidification leads to lower consumption of 
raw materials and energy, liquid alloy, labor, fluid 
technology and a significant decrease of time for 
approval of optimal technology. One of the major 
problems faced by designers of hardware technology 
is to achieve the possible removal of its thermal nodes 
inside castings. Simulation programs made offers to 
guide the process of solidification so that correctly 
dimensioning the designer and shrink head exterior or 
interior, thermal nodes castings should be completely 
eliminated. The emergence in recent times, the 
program flow and solidification simulation of 
composite materials make the new provisions to limit 
the matrix (metal) and particle or fiber. Phenomena 
that occur in these conditions are very difficult to 
simulate because of the multitude of factors that 
influence the solidification process of composite 
materials and make mathematical models that 
describe these processes to be cumbersome and error 
rising. Generally, the processes of solidification of 
alloys to be simulated in real conditions with very 
small errors; making the manufacture of castings has 
become much easier and it requires less time. This 
results in a saving of labor, materials and castings 
lower price, therefore more efficient foundry.  
 
References 
 
[1]. Godfroid, H. - Simulation Processes: Computer Simulation 
and Modeling, Workshop 50 th Int. Foundry Congress, Cairo, 
CIATF, 1983. 
[2]. Soporan, V., Vamos, C., Pavai, C. - Modelarea numerică a 
solidificării, Editura Dacia, Cluj – Napoca, 2003. 
[3]. Thomas, B.G. - Stress and Advanced Solidification Processes 
VI, Palm Coast, FL, March 21-26, 1993. 
[4]. Bratu C, Soporan V. -  CeEx 260/2006 - Modelarea 
matematică a proceselor care au loc la turnarea pieselor metalice, 
in vederea reducerii  consumurilor de materiale şi  energie, 2006 
[5]. Cocolas Sorin-Adrian – Lucrare disertatie – „Model 
experimental destinat modelarii matematica procesului de curgere 
la turnarea pieselor”, 2008. 
[6]. http://www.castech.fi/ 
[7]. http://www.ironcad.com/ 
[8]. http://tptc.iit.edu/Center/Resource/ApplicationOfSoftware/  
pamcast.html 
[9]. http://www.esi-group.com/products/casting/procast 
[10]. http://www.novacastfoundry.se/ 
[11]. http://www.afsinc.org/ 
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Software Used at Castings Production

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Software Used at Castings Production

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