The process of developing foundry technology using modeling is associated with a series of calculations in which certain technological solutions are “played” on a computer. Analysis of the results of intermediate calculations allows us to reasonably, quickly and purposefully find the optimal technology option. Of course, production realities may from time to time diverge from the conditions clearly specified during modeling, so one of the modeling tasks is to check the “stability” of the foundry technology found to fluctuations in some difficult-to-control production parameters.

Upon completion of foundry technology engineering, the customer receives a solution or set of solutions for the casting manufacturing technology, and the accompanying reporting documentation includes an in-depth scientifically based analysis of these solutions, covering both technical and economic aspects of production. At the request of the customer, the transferred material may contain files with calculation results and a program for viewing and analyzing them (post-processor). The fully computer-tested foundry technology can then be implemented at the foundry, with a high degree of confidence in its success! Our experience confirms the high accuracy of modeling predictions and the rapid return on investment in foundry technology engineering.

A typical set of initial data required from the customer includes:

• Geometric model of the casting and assembled mold (it is possible to construct a geometric model using our own resources). The geometric model of the casting must include all allowances and represent a single whole with the gating system, profits and other elements, because in SCM LP they model the physical process of solidification of a certain volume of metal poured into a mold with a cavity of arbitrary configuration, therefore the concept of individual casting fragments as technological elements fade into the background. Typically, the model received from the customer reflects the problematic, basic technology. During the modeling process, we transform this geometric model taking into account the current calculation results. The geometric model of an assembled form assumes the possibility of separating its different parts from the assembly in the form of separate bodies. This will allow us to take into account when modeling the fact that
• Data on the brand of casting alloy for selecting alloy properties from an extensive database (for “rare” alloys, properties are generated by chemical composition), pouring temperature for its duration, pouring equipment parameters for accurately modeling the process of filling the mold cavity.
• Data on the formulation of molding and core mixtures, the material of refrigerators and other elements installed in the mold. According to this data, the properties of the corresponding materials are selected from the database, or they are generated. Information is also required about the temperature of different parts of the mold before pouring and the ambient temperature.
• General description of the technological process. In SCM LP PoligonCast it is possible to simulate almost any casting method, taking into account any particular features of the process of obtaining a casting. This is facilitated by the versatility of the models included in the program, as well as the availability of tools that allow taking into account special conditions during casting.