Simulation Software Goes to the Next Level
Two new developments in the world of simulation software stand to elevate its role in metalcasting.
CHRISTOF HEISSER, MAGMA FOUNDRY TECHNOLOGIES INC., SCHAUMBURG, ILLINOIS XIANGDE LIU, TAO JING, TSINGHUA UNIV. DEPARTMENT OF MECHANICAL ENGINEERING, BEIJING, CHINA 模拟软件的新阶段 模拟软件有两个新的发展趋势，提升了它在铸造中的地位
CHRISTOF HEISSER，MAGMA 铸造技术公司，SCHAUMBURG, ILLINOIS， 美国, 刘祥德，荆涛，清华大学机械工程系， 北京，中国
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imulation software can be used to expedite the casting process by eliminating the traditional trial and error method of determining the best way to design a metalcasting pattern. However,
the software can be perceived as costly, and some simulation results do not achieve optimum casting designs. T e follow- ing developments in the simulation software industry may alleviate both of these concerns.
AUTONOMOUS OPTIMIZATION For many metalcasters, the development process for a
new casting often is limited by such factors as experience and trial-and-error. In the last two decades, however, casting process simulation has established itself as a tool that allows metalcasters to avoid numerous costly casting trials. Casting process simulation uses precisely defi ned fi xed
process parameters to provide results for each possible con- fi guration. Still, the casting process needs to be considered within a relatively large process window, as many parameters vary over a certain range. T e knowledge of a metalcasting process expert is therefore irreplaceable even when simula- tion is used. Usually, a simple optimization method is employed.
T rough sequential trials, “one dimensional search,” reviews and improvements, an acceptable process confi guration—a compromise—eventually is reached. Unfortunately, nobody knows whether this fi nal process confi guration represents a true optimization or how big the process window is. If every possible parameter change of the casting process were evaluated, an unrealistically high number of experiments or simulation runs would need to be performed. To address this concern, processes were developed to achieve valuable conclusions from a reduced number of
模
拟软件用来优化铸造工艺，取代了传统的 试错法。然而，人们认为模拟软件较贵， 并且一些模拟结果并不能实现优化工艺。
下面介绍模拟软件的新发展可以解决这两个问题。 自动优化
对很多铸造者来说，新铸件的开发过程受制于经验 和试错法等。然后，在过去的二十年中，铸造过程模 拟成了帮助铸造工作者避免无数的昂贵的铸造试验的 工具。
铸造过程数值模拟采用精确定义的固定的工艺参数 为各种方案提供结果。然而，铸造工艺需要在相对很大 的工艺窗口下进行考虑，很多参数在相当大的范围内变 化。因此，即使采用数值模拟，铸造工艺专家的知识仍 然是不可替代的。
通常采用简单的优化方法。通过一系列的试验、一 维搜索、评审和改进，才能最终得到一个可接受的工 艺，实际是各种妥协的结果。但不幸的是，没有人能 知道是否这个最终的工艺就是真正的优化工艺或者工艺 窗口有多大。如果评估各铸造工艺参数每一个可能的变 化，就要做大量（实际上也是不可能）的试验或模拟。 考虑到这个问题，要减少试验次数，从中得到有
CLICK HERE for more information on simulation software. 點擊此處獲得更多信息的仿真系統軟件。 Summer 2011
FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 57
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