Comparison of geometric visualization and finite difference method in analyzing the casting processes
Habib, Shah G. B.
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In this thesis, the capabilities of two analysis tools are discussed for two different casting processes - Permanent molding and High pressure die casting process. One of them is the easy-to-use pure geometry-based method and the other one is the more accurate and reliable tool based on the finite difference method. Both the tools have their own characteristics and capabilities. The geometry-based tool, CastView can produce the analysis result in just a few minutes, whereas the finite difference method based software. MAGMASoft gives the analysis result for the same model in a few hours. Sometimes, it may take a day or two, if the design is complex and the number of cycles for simulation is more than one. Despite the fact that, CastView uses only the part geometry itself to provide information about the part and its die casting features in visual and animated form, its primary advantage is that it requires virtually no setup and provides results very quickly. So a quick evaluation of the alternative parting and gating options can be checked considering the balance in the fill pattem and characteristics of the fill path. However, the simulation in MAGMASoft may take a longer time but results here are more accurate and reliable. We used two geometry models for two different casting methods to analyze the capabilities of these two tools. Techniques calculations of the distance to the gate from the various regions of the part and filling pattem are discussed in detail. The results found from the tools give us valuable information about the two methods such as their usefulness, efficiency, required skills, application areas etc. In this study we also tried to focus into the basic theories on which these two tools are based.