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Keywords : solidification, aluminium-silicon alloy, thermal analysis, computer simulation, temperature contours, near net shape, hot spot, gating system, latent heat of fusion, specific heat, thermal conductivity, carbon dioxide molding. Further work will be using MAGMAsoft for simulation of more complicated castings for sand and die casting processes.
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Overall, MAGMAsoft produces results that match the experimental data qualitatively and therefore the validation procedure is successful. The runner design is good because it ensures a simultaneous inflow of molten metal into the cavity through all gates. Directional solidification is achieved in the runner, however, there is a hot spot in the middle of the cast.
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A very good match between them is observed. The temperatures of control points in the sand mold and casting are used to compare the results between computational model and experiment in a qualitative manner. The validation is made against experimental data obtained from a thesis of previous research. Sand casting is ascertained for a block of dimension 160mm x 75mm x 36mm. This paper intends to validate the integrity and reliability of MAGMAsoft for the simulation of metal flow and solidification during the casting process. Various computational packages of CAD/CAE systems can be used to assist in mold design and prediction of casting quality ahead of mass production. Trial-and-error method to produce casting products from design to manufacturing is too costly and not effective. Foundries must be able to meet the just in time (JIT) requirement in order to survive in the competitive market and to achieve customer satisfaction. 1 Validation copy 7/12/05 11:58 AM VALIDATION OF MAGMASOFT SIMULATION OF THE SAND CASTING PROCESS Shamsuddin Sulaiman, Lim Ying Pio Department of Mechanical and Manufacturing Engineering, Universiti Putra Malaysia, UPM Serdang, Selangor ABSTRACT There is an increasing demand in manufacturing environment for the best quality of casting products at the right time and quantity.