Process Chaining Approach With Simulation: From Cast Ingot To Final Properties Of Forged Component

The aim of this study is to evaluate, through FEM software simulation, the quality and properties that can be achieved on a forged component, taking into account results of casting process used to produce ingot . In this article it will be presented how to chain ingot casting simulation to cogging and heat treatment simulation.

The FEM simulation software ProCAST allows to perform complete analysis of ingot casting process. On cast ingot it will be possible to perform thermo-fluid dynamics simulation coupled with thermo-mechanical stresses and deformations studies, including Microstructure (phase, grain size/shape/orientation) and Defects (Porosity, Segregation, Hot tearing).

The FEM simulation software DEFORM performs cogging analysis using as input data ProCAST ingot casting simulation results. DEFORM allows to evaluate final properties and soundness of forged components according to forming and heating operations, provides informations on thermo-mechanical and microstructural properties and gives details for plant dimensioning.

Actual simulation standards doesn’t link casting result to forging process inputs; in this way there are important missing information that reduce simulation reliability. The scope of this paper is to present this innovative and more robust chaining simulation approach which can be used to help the Ingot Casting and Forging industry to increase the quality and the productivity of their plants, processes and products.