Modelling and simulation of A segregates in steel castings using thermal criterion function Part II – Optimisation of real industrial cast part

The present paper is the second of two papers in which a methodology on how to exploit thermal criteria for modelling and optimising, i.e. minimising, the formation of A segregates in steel castings is presented. The first part of the paper dealt with incorporating one specific thermal criterion into a transient three-dimensional thermal fluid model inside a commercial simulation software package and validating this against experimental data obtained from a manufacturing foundry for a cast forging ram. In the second part of the present paper, the found criterion is then taken one step further by being applied to shape optimise the original casting layout of the forging ram where unknown optimal shapes and sizes of the top riser and chills are sought. This was carried out using genetic algorithms for establishing a better solidification pattern and thermal conditions inside the ram, which would eliminate the likelihood of centreline porosity and A segregates.