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Abstract

Simulation software dedicated for design of casting processes is usually tested and calibrated by comparisons of shrinkage defects

distribution predicted by the modelling with that observed in real castings produced in a given foundry. However, a large amount of

expertise obtained from different foundries, including especially made experiments, is available from literature, in the form of

recommendations for design of the rigging systems. This kind of information can be also used for assessment of the simulation predictions.

In the present work two parameters used in the design of feeding systems are considered: feeding ranges in horizontal and vertical plates as

well as efficiency (yield) of feeders of various shapes. The simulation tests were conducted using especially designed steel and aluminium

castings with risers and a commercial FDM based software. It was found that the simulations cannot predict appearance of shrinkage

porosity in horizontal and vertical plates of even cross-sections which would mean, that the feeding ranges are practically unlimited. The

yield of all types of feeders obtained from the simulations appeared to be much higher than that reported in the literature. It can be

concluded that the feeding flow modelling included in the tested software does not reflect phenomena responsible for the feeding processes

in real castings properly. Further tests, with different types of software and more fundamental studies on the feeding process modelling

would be desirable.

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Authors and Affiliations

M. Perzyk
A. Kochański
P. Mazurek
K. Karczewski

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