Progress on Numerical Simulation of Mold-Filling and Solidification Processes of Shaped Casting-Holding a Position in the World Academic Circle

Formation mechanism of shrinkage cavity and porosity of castings of different alloys was studied and hence some relevant criteria were established. A new method predicting the shrinkage cavity of spheroidal graphite iron casting was also established based on a series of experiments to study the effects of some key processing parameters. Mathematical model of the microstructure as well as the mechanical properties of spheroidal graphite iron casting was researched on the basis of solidification and thermodynamics theories. An integrated FDM/FEM system was studied, established and put into engineering application to study the thermal fields, stress fields and residual stresses of a machine tool bed casting and a diesel engine block casting. Computation efficiency and precision of numerical simulation of mold-filling process based SOLA-VOF method were extensively studied in order to meet the requirement for engineering application. Finally, an integrated CAD/CAE system under the concurrent environment was proposed, developed and put into engineering application.