Altair Inspire® Challenge #4: Overcome Porosity Issues with Casting Simulation

Matthew_Sauer1

Porosity is one of the major concerns in Casting Manufacturing. Air entrapment during filling and shrinkage porosity during solidification can compromise the quality and aesthetics of the casting product. Sometimes, it is not possible to 100% eliminate the porosity from casting. However, certain scenarios where optimizing the process, design change, and gating system can help to reduce the amount of porosity.

Input criteria:

Material – Aluminum 356,

Temperature – 718 C

Mold Material – Green Sand

Temperature – Atmospheric

Geometry attached (see x_b file)

Tips: Use the Gravity Casting process and necessary casting components.

Level: Easy

Level: Medium (Optional) Design multi-cavity assembly and run a simulation with the filling system included.

Product Required: Altair Inspire Cast

The solution can be attached in the comment section of this post. The desired output format is a .icast file with results accompanied with a JPG illustrating your results.

The solution to the Challenge ‘3D printed Structural Steel Connection Design’ Can be found here.

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Kunal Pandit_21294

Dear Matthew,

I trust this message finds you well.

I am writing to request your assessment of the attached snapshots, which pertain to the porosity and the filling of the last air in the bracket casting. For which I used overflow component Also.

   

Your expertise and insights on these matters are highly valued.

Best regards,

Kunal P.

Matthew_Sauer1

Kunal Pandit_21294 said:

Dear Matthew,

I trust this message finds you well.

I am writing to request your assessment of the attached snapshots, which pertain to the porosity and the filling of the last air in the bracket casting. For which I used overflow component Also.

   

Your expertise and insights on these matters are highly valued.

Best regards,

Kunal P.

Nicely done, Kunal!  Thanks for your submission.

Kunal Pandit_21294

Matthew Sauer_21269 said:

Kunal Pandit_21294 said:

Dear Matthew,

I trust this message finds you well.

I am writing to request your assessment of the attached snapshots, which pertain to the porosity and the filling of the last air in the bracket casting. For which I used overflow component Also.

   

Your expertise and insights on these matters are highly valued.

Best regards,

Kunal P.

Nicely done, Kunal!  Thanks for your submission.

Thank You, Matthew!