Design information revealed by CAE simulation for casting product development

Research output: Chapter in book / Conference proceedingConference article published in proceeding or bookAcademic researchpeer-review

1 Citation (Scopus)


In casting product development, the design and development paradigm is shifting from traditional trial-and-error in workshop to simulation-based virtual realization in up-front design process. The traditional trial-and-error approach appears to be more heuristic know-how than deep scientific analysis and calculation. The knowledge and know-how acquired through trial-and-error is difficult to be applied in similar product development as a little change of product geometry would lead to significant changes of casting design, tooling design, melt flow pattern, and process route and parameter configuration. CAE simulation technology, which models the entire casting system and imitates the dynamic behaviors of the system in working conditions, provides complete design information for generating, verifying, validating and optimizing design solutions for process and die design via simulation of the entire casting process. In addition, the design information provided helps reveal and predict the final product output in terms of product microstructure, defects, quality and properties in such a way that the optimal design solution can be determined. In this paper, the modeling of casting processes is first articulated and the associativity between the casting process, modeling, simulation and output variables are presented. A simulation-based paradigm for revealing the information in different categories is described and how the information helps design solution evaluation and verification is articulated. Through case study, the information in high pressure die casting filling process is presented and the phenomena in filling process is further explained.
Original languageEnglish
Title of host publicationGlobal Design to Gain a Competitive Edge
Subtitle of host publicationAn Holistic and Collaborative Design Approach Based on Computational Tools
PublisherCSREA Press
Number of pages10
ISBN (Print)9781848002388
Publication statusPublished - 1 Jan 2008
EventGlobal Design to Gain a Competitive Edge: An Holistic and Collaborative Design Approach Based on Computational Tools - Sanya, Hainan, China
Duration: 14 Jan 200816 Jan 2008


ConferenceGlobal Design to Gain a Competitive Edge: An Holistic and Collaborative Design Approach Based on Computational Tools
CitySanya, Hainan


  • CAE simulation
  • Casting process
  • Integrated product and process design

ASJC Scopus subject areas

  • Computer Graphics and Computer-Aided Design
  • Computer Science Applications
  • Control and Systems Engineering
  • Industrial and Manufacturing Engineering

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