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CASTING SIMULATION BY THE
FINITE ELEMENT METHOD

COMPUTERING CRITERIA:
FUNDAMENTALS
Navier–Stokes
equations
Turbulence modelling-
Smagorinski´s model
Temperature
equation
Meshing Elements 2D: Triangular

NASTRAN 3D: Thetraedral
COMPUTERING CRITERIA:
OTHER CONSIDERATIONS
NIYAMA CRITERION: SOLID FRACTION: A/L
POROSITY PREDICTOR When the melt state is mushy, solid fraction
indicates what percentage volumetrically is
Temperature already solid.
gradient
G STATE SOLID: SOLID FRACTION=1
 1.0K1/2 min1/2 cm 1 
T STATE LIQUID: SOLID FRACTION=0
A
 775K1/2s1/2 m 1
L
Cooling rate
Temperature
Composition %
The relationship between shrinkage porosity and the Niyama criterion is shown
schematically in Fig. 1. For sufficiently large Niyama values, no shrinkage porosity forms.
When the Niyama value decreases below a critical value, Nymicro, small amounts of
micro‐shrinkage begin to form. As the Niyama value decreases further (note the log scale
on the x‐axis), the amount of micro‐shrinkage increases until it becomes detectable on a
standard radiograph. This transition occurs at a second critical value, Nymacro. The
amount of shrinkage porosity continues to increase as the Niyama criterion decreases
below Nymacro. It should be emphasized that the Niyama criterion only predicts feeding‐
distance related shrinkage; it does not explicitly predict hot spots in a casting, and it does
not predict gas porosity.
NIYAMA CRITERION
NIYAMA CRITERION APPLICATION
Solidific.
time
90%
775 K1/2 s1/2 m-1 Sound point
Risk of
macroporosity
FEA FUNDAMENTALS
A typical work out of the method involves
Dividing the domain of the problem into a collection of subdomains, with

each subdomain represented by a set of element equations to the original
problem
Systematically recombining all sets of element equations into a global
system of equations for the final calculation. The global system of
equations has known solution techniques, and can be calculated from
the initial values of the original problem to obtain a numerical answer.
Explicit and implicit methods are approaches used in numerical analysis for
obtaining numerical approximations to the solutions of time-
dependent ordinary and partial differential equations, as is required in computer
simulations of physical processes.
Explicit methods calculate the state of a system at a later

∆
time from the state of the system at the current time
Implicit methods find a solution by solving an equation , ∆ 0

involving both the current state of the system
Implicit methods require an extra computation (solving the above equation), and they can
be much harder to implement
Implicit methods are used because many problems arising in practice are stiff, for which the
use of an explicit method requires impractically small time steps (Δt) to keep the error in the
result bounded. For such problems, to achieve given accuracy, it takes much less
computational time to use an implicit method with larger time steps, even taking into
account that one needs to solve an equation more difficult to solve at each time step.
https://en.wikipedia.org/wiki/Explicit_and_implicit_methods
STAGES OF FEA ANALYSIS
Geometry definition
Mesh generation
PREPROCESS Boundary conditions
Assingment of Properties
Other operations: mesh refinining
SOFTWARE Linear equations systems resolution

CALCULATION and the values of different functions
SOLVER
or magnitudes are obtained for each
node.
Post-process means the visualization of the
simulation results; this is perhaps the most
important step of all the casting simulation steps;
here is where we read and analyze the simulation
POSTPROCESS
results. Once the calculation is finished, we can
visualize the results of this simulation. There are
many different ways to do it, like colour maps,
vectors, iso-surface curves, virtual thermocouples,
etc.
TYPES OF MESH
The difference between structured

and non-structured meshes can
easily be seen graphically
ELEMENT SIZE
DECREASING THE ELEMENT SIZE ALLOWS US TO

REPRESENT BETTER THE GEOMETRY SHAPE
2D MODEL BASIC MESH REFINED MESH

http://fea‐cae‐engineering.com/fea‐cae‐engineering/element_types.htm
TYPES OF ELEMENTS
Triangular 2D element with 3D element consisting of one

three nodes at the corners volumetric tetrahedron with 4
nodes on the corner
TETHAEDRAL ELEMENTS AND NODES
NODES
ELEMENT
ONLY EXTERNAL NODES

EXTERNAL AND INTERNAL NODES
70x70 mm2
Distance Distance Last

gate- riser 1 riser-riser distance
L1 (mm) L (mm) L2 (mm)
Experiment 1 355 226 133
Empirical solution 290 226 198
V. Miguel-Eguía*, M. C. Manjabacas-Tendero, N. Medina-Ríos
Prediction of the effectiveness of the feeding system of carbon steel sand castings using the solid fraction criterion. Application to square bars.
Int. J. Materials and Product Technology, Vol. 53, No. 1, 2016, Inderscience Enterprises Ltd.
Distance Distance Last

gate- riser 1 riser-riser distance
L1 (mm) L (mm) L2 (mm)
Empirical solution 290 226 198

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CASTING SIMULATION BY THE

FINITE ELEMENT METHOD

Meshing Elements 2D: Triangular

Dividing the domain of the problem into a collection of subdomains, with

Explicit methods calculate the state of a system at a later

Implicit methods find a solution by solving an equation , ∆ 0

SOFTWARE Linear equations systems resolution

The difference between structured

DECREASING THE ELEMENT SIZE ALLOWS US TO

2D MODEL BASIC MESH REFINED MESH

Triangular 2D element with 3D element consisting of one

ONLY EXTERNAL NODES

Distance Distance Last

Distance Distance Last

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