How to solve complex problems in foundry plants - Future of casting simulation - Future o

Abstract

Although the computer simulation of casting has progressed dramatically over the last decades, there are still many challenges and problems. This paper discusses how to solve complex engineering problems in foundry plants and what we should do in the future, in particular, for casting simulation. First, problem solving procedures including application of computer simulation are demonstrated and various difficulties are pointed-out exemplifying mainly porosity defects in sand castings of spheroidal graphite cast irons. Next, looking back conventional scientific and engineering research to understand casting phenomena, challenges and problems are discussed from problem solving view point, followed by discussion on the issues we should challenge such as how to integrate huge amount of dispersed knowledge in various disciplines, differentiation of science-oriented and engineering-oriented models, professional ethics, how to handle fluctuating materials, initial and boundary conditions, error accumulation, simulation codes as black-box, etc. Finally some suggestions are made on how to challenge the issues such as promotion of research on the simulation based on the science- oriented model and publication of reliable data of casting phenomena in complicated-shaped castings including reconsideration of the evaluation system.