Intended for the designer of automotive components, this paper emphasizes the importance, and feasibility today, of using casting modeling early in the design process. Usage of computer modeling for metal casting has expanded greatly in just the past few years. This is due to both advances in computer power, and to the economical benefits from modeling. Benefits include optimization of the process parameters to ensure sound parts, reduction of scrap, and minimization of defects. Given the complexity of automotive castings and the expanded range of materials being cast, computer simulation has gained an important role with designers as well as foundrymen. However, most computer simulations to date have focused on solidification and shrinkage modeling. Only recently has modeling begun to include the metal flow behavior with its inherent complexity. Recent advances in casting-specific flow modeling are showing great opportunity to provide additional improvements to automotive castings, especially for powertrain components. Specifically, this includes the processes of lost foam, high-pressure die-casting, and even with sand-core blowing. This paper covers the recent developments with casting modeling in all three casting process areas.
