The process of computer simulation illustrates the way a casting is filled and how the alloy is allowed to cool. By simulating the process conditions to observe 3-D fill and solidification, researchers will be able to predict potential defects in the casting and redesign the process to eliminate the defects, before making actual castings. Activities will compare theory to practice.

Prerequisites & Corequisites: Prerequisite: IME 3520 or previous metal casting experience.

Credits: 3 hours

Lecture Hours - Laboratory Hours: (2 - 2)

1. Understand the importance of metal casting simulation. (j)
2. Identify and model the conditions of 3-D solidification simulations. (a, b & f)
3. Analyze and interpret the simulation data and solve metal casting related problems. (c & k)
4. Optimize metal casting designs. (e & f)

Letter in parenthesis refers to ABET EAC Criterion 3 / TAC Criterion 2, categories a – k.

Objective 1:

1. To be familiar with the current research literature in the metal casting simulation & solidification. (5)
2. To understand the theory of solidification. (1-9)

Objective 2:

1. To identify potential defects found through solidification simulation . (3, 6, 7 & 9)
2. To understand process control through solidification simulation. (6-9)

Objective 3:

1. To understand gating and risering design procedures in relation to solidification simulation. (1, 2, 3, 4 & 5)
2. Generate computer files t o analyze and interpret a three dimensional solidification simulation models, using SOLIDCast, NovaFlow& Solid, SIM TEC / WinCast, and MAGMA softwares. (1, 2, 3, 4 & 5)

Objective 4:

1. To optimize casting designs in relation to solidification simulation. (1, 2, 3, 4 & 5)

Numbers in brackets refer to the method of evaluation as listed in Evaluation.

Technology of Metalcasting, Fred P. Schleg, American Foundry Society.

Course Coordinator:

Sam Ramrattan
Western Michigan University
F-218 Parkview Campus
Kalamazoo, Michigan 49008-5336
Phone: 276-3373
Email: sam.ramrattan@wmich.edu