Title: Applications of optimisation in metal casting

Authors: Darius P.K. Singh, Ravi Vijayaraghavan

Addresses: Alloy Wheel Plant, Ford New Zealand, 70 Plunket, Avenue, Win, New Zealand. Materials Science Department, Ford Research, Laboratory, MD 3182/Rm 2122, P0 Box 2053, Dearborn, MI 48121-2053, USA

Abstract: Many major foundries are using software such as ProCAST™ and MagmaSOFT™ to simulate filling and solidification of castings, for process design. A number of input parameters to these casting simulation softwares (such as material properties and boundary conditions) are not well known. This has motivated the need for an optimisation tool, which uses an inverse modelling approach to determine these parameters given the experimental results. The objective of this paper is to present formulations of different optimisation problems that arise in the casting process. Use of efficient and robust optimisation-based methodologies to solve these problems can play a major role in reducing costs and improving productivity and quality of cast products. This paper represents applications of optimisation in mould filling, heat transfer, solidification and microstructure evolution.

Keywords: casting simulation; filling, microstructure; optimisation; process design; solidification.

DOI: 10.1504/IJVD.2001.001906

International Journal of Vehicle Design, 2001 Vol.25 No.1/2, pp.40-52

Published online: 18 Aug 2003 *

Full-text access for editors Full-text access for subscribers Purchase this article Comment on this article