Casting process simulations are used by Sarginsons to predict and avoid defect formation in their Sand, Gravity and Low pressure castings. Their integration into the structural analysis of components can enable automated structure and process-optimized castings. Sarginson uses three distinct simulation strategies to expedite component performance, improve quality, minimise product development times, avoid repeat testing and enable FEA studies, including accurate crash simulations.
Casting simulations of sand, gravity and low pressure casting processes virtually model physics and thermodynamic laws, in the light of real world variables, to predict how liquid aluminium will behave. Any number of parameters can be adjusted to find virtual solutions in hours that would take weeks if physically tested. This minimises the time, cost, and number of iterations delivering high quality sand, gravity and low pressure casting first time, every time.
At its most basic, and practiced by most good foundries, are simulations for the prediction of directional solidification. These allow potential porosity and other defects to be identified at the design phase avowing defects, caused by poor cooling, to be avoided. Sarginsons has combined three commercial packages, as each takes a different technical approach, produce a combined output that extracts the best features of each.
Sarginsons has developed its own Digital Twin Simulation strategy which, uniquely, can predict the TYE and Fatigue performance of a casting at any point on the component form. Other foundries assume a homogenous TYE performance across the entire form. It also is the only foundry that can export this data to FEA meshes for further work, including virtual crash testing.
The ability to predict TYE performance at any point allows Sarginsons to use Topological Optimisation packages to find the optimum design for weight / performance for any given component. This is a huge step forward as it enables optimum lightweighting but, also allows the creation of one piece castings in place of multiple components. Sarginsons is seeing a minimum of a 20% weight reduction when components are topologically optimised.
Sarginsons is developing software, PIVOT, that will combine all three of its simulation programmes into one package, which negate the need for foundry engineers to help design components This software won’t be available until 2027 so, until then, each stage and iteration of the simulation process, and the CADCAM, has to be run and operated by specialist engineers.
Even after this PIVOT software is available, foundry engineers will oversee the sand cast production process, particularly the feeding and gating strategies, as well as metallurgy and the finer modifications. Furthermore, any simulation, even those as accurate as Sarginsons, will still be unable to perfectly predict the actual, real life performance of a sand casting, as there are simply too many variables, so manual adjustments will probably still be required.
Sarginsons puts a lot more focus on metallurgy than most, particularly alloy cleanliness, perfect additive dosing, alloy temperature and alloy origin. This is particularly important in sand castings, where cooling rates are exaggerated. Sarginsons has 3 metallurgists and is developing its own recycled aluminium alloy that has the same mechanical strength as primary aluminium; another world first.
Expertise is required to set appropriate parameters for the casting simulation software to run effectively for any chosen component. Critical parameters may include:
Temperatures – Sand, Metal, Factory, Tools, Equipment, Metal Transport
Cleanliness – Oxide, Biofilms, Iron and Environmental Issues.
Humidity – Sand Moulds, Sand Cores, Tool surfaces.
Alloys – Silica, Iron, Oxides contamination.
Design – Undercuts, Bosses, Soles, Protrusions, Thickness, Finishes.
Flow Rates – Variable
Mould Material – Sand acidity,
Cleaning Agents –
Casting is the most complex of all manufacturing methodologies as it has countless variables to contend with, any of which can result in a defective product. Metal temperature, mould material, flow rates, atmospheric contamination, cooling rates and so on all play a part in making casting a delicate operation. This means getting a component to work first time, without simulations, is almost impossible and so, leads to over engineering as designers play safe, knowing any mistake can be massively expensive in terms of time and money.
The most important issue in casting is the way and speed that metal cools, particularly in sand castings. This cooling can be controlled to a degree through cooling techniques, such as helicoil inserts, ceramics, sand type as well as modified runners and risers, but without simulations you’re flying blind. Predicting metal solidification is is a fiendishly complex science with numerous different approaches, so Sarginsons combines 3 distinct solidification programmes and merges the results.
The second most important variable in casting is component design. So often we areas of high stress countered by the addition of extra metal, but this just makes the situation worse.
So, simulations help get components designed properly and more quickly with additional iterations optimising TYE mechanical strength and reducing mass. All can be physically tested using one of Sarginsons 3 methods of sand casting – Traditional, Counter gravity and Low Pressure sand.
We don’t recommend using our entire simulation suite unless weight, strength and mechanical performance are important, but it is good to know that those options are there in case something goes wrong, or design parameters change.
1. Turbulence Control
2. TYE and Fatigue Predictions
3. Microstructure Understanding
4. Optimised for Lightweight
5. One Pieve Components
6. Targeted, Smart Cooling
7. Faster Development
8. Greater Design Potential
Everything: Trying to develop cast component designs without simulating every aspect possible, and then producing perfect sand prototypes, is financial negligence. Castings become better in every way once a full understanding of every aspect of that component is simulated. And the relatively small cost is repaid a thousand times.
Control of Mechanical Strength: The only method of predicting TYE mechanical performance, even in sand castings, at any point on the component’s form, not a homogenous one size fits all general estimation. This allows the full range of casting techniques to be brought to bear on problem areas, rather than treating the entire component – targeted treatment not major surgery.
Reduced Testing Costs: Simulations allow rapid virtual iterative testing which can do in hours what would’ve taken months. This ensures that when expensive physical testing is undertaken, particularly involving a whole car, the results will pass any required objectives.
Quicker Development Times: Simulations allow an infinite number of design parameters to be tested, changed and retested in days. This allows rapid iterative design techniques to be deployed for the first time in the casting world, allowing optimal product design to be developed well within development timelines.
Better communication and collaboration: the detailed visualisation provided by casting simulation software allows foundry engineers to more easily communicate their designs and ideas to customers. 3D models, animations and detailed reports help in understanding the casting process, making it easier to collaborate on design improvements or adjustments before production begins.
Casting simulations for new components are immensely valuable but it is possible that the ability to remediate problem castings virtually, without stopping production or endless physical testing may be even more valuable.
Sarginsons is dedicated to the exploitation of technology to create better, cheaper, stronger and more environmentally friendly components. Simulations constitute the front line, but behind this there are any number of new techniques and processes that allow Sarginsons to offer an unequalled service in both sand, low pressure and gravity castings.
Casting simulations are a vital part of any cast component development. They enable radical improvements in every area, with problems either designed out or treated by directly targeting identified problem areas: a technique particularly useful for remedial casting design.
No foundry in the world offers the range of technological solutions and simulations as Sarginsons. This is the same as saying no foundry in the world can deliver better performing, cheaper or more capable castings as Sarginsons.
By enabling foundry engineers to visualise every step of the casting process quickly, the software helps the experts optimise critical parameters without the need for customers to invest in repeated patterns and tooling. Whether developing new products, or optimising the sand casting of existing products, our experts at Sarginsons Industries will continue to use the best casting simulation software for the benefit of customers.
Contact us now to find out more about our sand casting expertise, and how we can deliver high quality new and existing products for your business.
Torrington Avenue, Coventry,
West Midlands, CV4 9AG