Better practice for effective utilization of simulation software

Introduction:

Casting simulation software has transformed the foundry industry by enabling engineers to visualize molten metal flow, predict defects, and optimize gating and riser designs before a single mold is poured. Yet, like any powerful tool, its true potential is only unlocked when used effectively.

In this article, we’ll explore the better practice for effective utilization of simulation software

What is Casting Simulation:

Simulation is the process of imitating a real phenomenon using a set of mathematical equations implemented in a computer program. Casting simulation has become a powerful tool to visualize mold filling, solidification and cooling, and to predict the location of internal defects such as shrinkage, porosity and cold shuts etc., It can be used for troubleshooting existing castings, and for developing new castings without shop-floor trials.

Better practice for effective utilization of simulation software:

1. Strategies planning with CFT team
   1. For new RFQ projects, by conducting CFT meeting and brainstorming with all members on product gating design and preparing various Methoding concepts.
   2. These concepts can be modelled and proceed for simulation and results can be compared for all Methoding concepts and best design with better yield and less/no defects can be identified and same can be proceed with shop floor trails.
   3. By involving CFT for simulation will help to produce new ideas and concepts and thus leads to cut short product development time.
2. Knowledge on process
   1. Simulation engineer should have proper training and experience in process as inputs to be provided in simulation should match with actual shopfloor feasible conditions.
   2. Proper training required for design and simulation engineer to understand Root cause assessment and steps need to overcome issue.
   3. Any improper understanding of root cause will further delay in solving issue.
3. No assumptions in input data
   1. Simulation software results directly depend on simulation inputs provided.
   2. No assumptions in input data should be encouraged.
   3. Before setting of simulation, engineer must circulate process parameters sheet which will have all inputs that they are going to consider for simulation.
   4. If any improvement/changes can be suggested before proceeding for simulation activity.
4. Effective training and tutorial utilization
   1. Proper training is required for simulation engineer on tool utilization for simulation setup, execution, and results interpretation.
   2. If any deviations in simulation setup results in deviation in defect prediction.
   3. Detailed SOP to be prepared and simulation engineer need to be trained for simulation setup, execution, and results interpretation.
   4. We suggest every day 2 simulation setup to be done for new users to understand tool and get hands on experience in tool.
   5. Tutorials provided to be revised thoroughly by new users. This will help to reduce simulation setup time and effectively increasing productivity.
5. Maintaining record of simulation data
   1. Maintaining record data for simulation is good practice.
   2. Include all details such as date, Project name, Revision, Process parameters, Simulation observation points will help user to refer for any future requirements.
   3. Collection of data and analyzing data helps us to understand frequent defects and optimization performed to overcome defects.

Conclusion:

In short, the real power of casting simulation lies not only in the software itself, but in how intelligently it’s used.

When foundries feed it accurate data, involve the right people, and treat every iteration as a step toward optimization, simulation transforms from a troubleshooting tool into a profit-generating advantage.

Master the process, and you don’t just eliminate defects — you design success before the first pour.