An integrated approach to computer simulation of casting processes

The casting process combines many complex physical phenomena. With recent increases in computing speeds and reductions in the cost of machines, it is becoming viable to model even the most complex physical processes. The UK casting industry, supported by the UK Department of Trade and Industry (DTI) in its Castings Initiative, has been developing a flexible approach to computer modelling of casting processes. The Casting Initiative is promoting work in both the development of software and of verification of software and methods. A core computer program is being developed by FEGS Ltd to provide a user-friendly casting-specific front end and a common link between different solution packages. An environment has been developed that includes a modified version of DYNA3D, TOPAZ3D and a number of other controlling programs. This software environment is referred to in this paper as CAST3D. It is essential that any software for the simulation of casting should be validated. CAST3D and a number of other commercial codes are being extensively verified in a three year program of parallel testing and simulation. This paper addresses the following three subjects: the UK DTI´s Casting Initiative; a framework approach to coordinate pre- and post-processing and solving software, implemented by FEGS Ltd; and DYNA3D extended for use in the simulation of casting processes