Patent ID: 6298898
Filing Date: 2001-10-09
Classification: B22D

Abstract:
A method of optimizing cycle time and/or casting quality in the making of a cast metal product defined by a CAD product model, comprising the steps of:(a) providing a computer casting model using objective functions that simulate the filling and solidification of the CAD product model within a die, the casting model being subdivided into contiguous regions with each region having its own terms in at least one of the objective functions for thermal conductivity, heat capacity and cooling time period;(b) adapting the objective function terms based on experimental data to calibrate the casting model measured thermal data, derive matching heat transfer coefficients for each region, and simulate filling and solidification of the product within said die; and(c) constraining the objective functions to ensure directional solidification along the series of contiguous sections while optimizing thermal conductivity and heat capacity, and iterativately evaluating the constrained objective functions to indicate which regions ofthe casting model can have chills, cooling channels or insulation added to effect improved cycle time and/or casting quality.