Computer simulation of railway wagon brake disc casting

¹ Technical University of Kosice, Department of Metallurgy, Park Komenského 14, 040 01 Košice, Slovakia
² Technical University of Košice, F BERG, Logistics Department, Park Komenského 14, 040 01 Košice, Slovakia
³ Technical University of Košice, FVT, Department of Computer Aided Manufacturing Technologies, Bayerova 1, 080 01 Prešov, Slovakia

^* Corresponding author: gabriel.fedorko@tuke.sk

Abstract

CAD systems serving as the model for real industrial processes are almost an inseparable part of manufacturing in many industry branches. The use of simulation programs in the foundry industry is perceived as a tool for the visualization of the processes involved in the production of castings. They are also used to resolve possible issues and imperfections before the production begins. Consequently, it enhances the quality and reduces product-manufacturing-related financial costs. The paper tackles the issue of how to resolve the occurrence of defects – shrinkages in the railway wagon disc casting while using a simulation program. The 3D model of the casting and of the system of gates was constructed in the CATIA CAD system. The mere simulation of the casting and solidification process was done in the NovaFlow&Solid program. After evaluating the results of the simulation, the correction of the casting and gates was made in order at once to enhance the quality of the casting and reduce the production costs in the manufacturing of this casting. In the production of the brake disk casting, the main issues are little usage of molten metal during casting and the considerable occurrence of shrinkages, which causes the increased economic costs of its production.