Modeling the Solidification of Foundry Castings

A comprehensive technique is described for performing the simulation of the solidification of foundry castings. A finite element method (FEM) mesh is produced for the pattern of the part, using geometric modeling techniques. Results are presented to demonstrate selection rules for the mesh size. The size of the heat transfer problem is reduced by replacing the FEM mesh in the mold material by appropriate boundary conditions on the surface of the casting. The boundary conditions are found automatically by a program which relates local surface curvature on the part to a pre-calculated library of solutions. Methods for ensuring that all of the latent heat of fusion is included are presented, and comparisons are made between different solution methods.