Simulation of Gravity Filling in a Silica Sand Mold with Gray Cast Iron (EN-GJL-250)

This study presents a simulation modeling of the gravity filling of a sand casting mold with gray cast iron EN-GJL-250. An analysis of the fluid flow, the nature of the filling of the casting mold, and the possibility of forming defects, such as voids and porosity due to metal shrinkage during the crystallization process, was performed. The simulation was performed using specialized software for simulating metal casting processes. The software allows the modeling of fluid dynamics and thermal conditions during the filling of the casting mold. The results obtained show the influence of the design of the sprue system, pouring temperature, and casting geometry on the movement of the fluid flow and the crystallization of the metal. The simulation also allows the visualization of turbulence and temperature gradients, helping to localize areas prone to defects. The results of this study could improve the quality of the specific casting and aid in selecting appropriate technology for the casting of a small series of high-quality castings.