Increasing the Capabilities of Computer Process Modeling with Applied Programming Interface

Abstract

Computer-based process modeling has long been used for simulating the casting of metals. The information from these simulations has allowed metalcasters to reduce the occurrence of some defects that result from the metal’s volumetric contraction or entrainment of gasses while filling of the mold cavity. The majority of the analysis of the casting process has been limited to the metallic casting itself rather than the mold that contains the metal. High-temperature characterization of molding materials has yielded an increased understanding of the condition of the mold and core during solidification. Properties such as thermal expansion, high-temperature reactions, and changes in surface viscosity and decomposition gasses have yielded an increased understanding of the casting process. By using actual high-temperature mechanical property data generated at the foundry, the accuracy of the solidification modeling is improved and the range of capabilities is increased. The use of applied programming interface code can extend the software’s capabilities and yield additional information on the condition of the mold before, during and after solidification. Although once limited in release, new versions of the process modeling software will include the capability to both optimize process variables and develop material-specific datasets that increase both the accuracy and extend the capabilities of the analysis. Using applied programming interface code, the range of capabilities of the process modeling software can be extended to include information on veining defects, final casting dimensions and decomposition gas generation that can result in porosity defects or changes to the thermal properties of the mold.