Sustainable casting processes through simulation-driven optimization

Abstract

Abstract Since the 1980s, the evolution of the computing power as well as the advances in numerical modeling techniques have allowed for the development of accurate casting simulation solutions. Although casting processes involve a series of diverse phenomena such as turbulent flow, porosity formation, and various time scales, modern simulation packages are capable of accurately modeling both the filling and solidification stages of the process. Thus foundry engineers can nowadays predict the characteristics of the final cast products such as residual stresses and defective locations without having to perform numerous time-consuming trial-and-error experiments. On the other hand, one of the applications undergoing intense investigation during the last few decades has been the successful implementation of integrated modeling, simulation, and optimization frameworks in manufacturing processes. Most of the case studies implemented focus on the optimization of three main process characteristics closely related to sustainability: (1) yield, (2) energy efficiency, and (3) product quality. The aim of this chapter is to provide an overview of the modeling techniques and optimization frameworks, which have been successfully applied to the simulation of casting processes with respect to the aforementioned process characteristics.