Abstract
This paper presents a new approach to analyze the quality of ductile iron castings through simulations and experiments. Standard tensile test specimens are considered as simple cast products for which a multi-cavity mold is designed, simulated, and optimized to minimize porosity using MAGMASoft. X-ray imaging, hardness measurement, and tensile testing are done for selected specimens produced using optimized mold design. Next, finite element simulation of tensile testing until fracture is done in ABAQUS using elastic-plastic material model and porous metal plasticity model. Simulation results for sound specimen are found to be in good agreement with the experimental results. Since mold design optimization is solely based on porosity minimization, no porosity is observed in the final mold design. However, if multi-criteria optimization of mold is done, the specimens may show some porosity which can be integrated in the developed finite element model of tensile testing. It is concluded that simulation-based mold design optimization can produce nearly defect-free castings and at the same time exhibit the similar mechanical properties as their sound counterparts produced with other manufacturing processes.