Process design optimization through numerical experimentation for a brake disc casting

Abstract

An integrated numerical model is applied to simulate the mold filling and solidification phenomena as well as to predict the occurrence of the related casting defects for a brake disc casting. The goal is to conduct numerical experimentation to improve the running and gating system of the brake disc casting to obtain better casting quality. A computer-aided engineering software based on the finite element method is employed in this study. Numerical simulations are conducted for the brake disc casting with a preliminary running and gating system. The mold filling and solidification phenomena are examined to predict the occurrence and extent of the casting defects. They are found to be consistent with the defects observed in the actual casting. Based on the findings of the simulated results, a modified running and gating system is then proposed. The mold filling and solidification phenomena for the modified design are simulated. The results show that the problem of casting defects is alleviated with use of present results. © 2008 The Japan Institute of Metals.