Lost Foam Casting

Simulation of processes where a model made of polystyrene or similar material is used, which vaporizes when molten metal is poured into the mold, allowing for complex and detailed shapes in the final casting.

PoligonSoft enables the detection of potential defects during the early phases of the technological process design and develops an efficient methodology, in addition to reducing the number of necessary tests and speeding up the introduction of casting into the production cycle.

  • Filling Dynamics
  • Macro and Microporosity
  • Residual Stresses
  • Cracks (Hot and Cold)
  • Deformations and warping
  • Hydrostatic Pressure
Product

Cost and Time Reduction

Save significant costs in materials and labor, in addition to reducing product development time.

Improve Quality and Precision

Prevent and correct casting defects, such as porosity, air inclusions, or solidification issues.

Process and Design Optimization

Experiment with different variables of the casting process to find the most efficient configuration.

Cast iron pouring with lost foam model

Study of porosity in Lost Foam casting of a flanged tee for ChugunSpecStroy

  • High-strength cast iron - VCH50
  • Mold - Quartz sand 1K1O2O3
  • Mold temperature - 20°C
  • Pouring temperature - 1500°C
  • Sprue diameter - 48 mm
  • Filling time ≈ 30 seconds
  • Molding box size in clear - 1500x1500

The company provided a model of the piece and the proposed casting process to check for the possibility of defects.

Filling (speed)

Filling (temperature distribution)

Solidification (thermal nodes)

Solidification (temperature distribution)

Porosity Formation

As a result of the simulation, it was determined that it is not possible to obtain a quality piece using the proposed technology.

The porosity can reach 100% due to the absence of feeders at the locations of thermal node formation on the flanges.

To correct the problem, significant mold correction is required, with the addition of feeders in the problem areas, as well as the elimination of holes in the flanges, which apparently were included in the model due to an error.

Process Optimization and Design

Use of PoligonSoft in the casting of 'Gearbox' at LLC 'Kirovsky Zavod Electromagnitov Dimal'.

The main task in the manufacturing of small batches of castings is their rapid production with minimal cost in technological development and preparation for production. This challenge was to be addressed in the development process of the 'Gearbox' casting, made of 35L steel, using the lost foam casting technology.

Control operations after the manufacturing of the first casting revealed shrinkage cavities and porosity in the areas of contact with the gearbox cover. After this, it was decided to abandon real experiments and determine the causes of defects using the PoligonSoft computer modeling system for casting processes.

The company was provided with a temporary license for this software, and all the work to modify the technology was carried out independently by the foundry workshop specialists.

Porosity Distribution in the Casting

Porosity Distribution in the Casting

Porosity Distribution in the Casting