The quality of steel castings was analyzed in this paper through integrated simulations and experiments. The standard tensile specimens were considered as actual cast products. These specimens were prepared using a multi-cavity mold which was initially designed using standards and foundry practices followed by its optimization in casting simulation software MAGMA Soft. The specimens produced with the optimized mold were then tested under tension until fracture. Porosity predicted in casting simulations was integrated to finite element simulations of tensile testing. Simulated and experimental results were compared, discussed, and conclusions drawn. Some specimens indicated discrepancy in the simulated and experimental stress-strain behavior; however, porosity was not found responsible for this disagreement as confirmed through X-ray imaging and by comparing the simulated and actual porosities. It is concluded that the quality of cast specimens is compromised due to ineffective heat treatment which should be done in a more controlled manner for improved quality and performance of castings produced using multi-cavity molds.

通过综合模拟和实验分析了钢铸件的质量。标准拉伸试样被认为是实际的铸造产品。这些样品是使用多腔模具制备的，该模具最初是使用标准和铸造实践设计的，然后在铸造仿真软件MAGMA Soft中进行了优化。然后，在张力下测试用优化模具生产的样品直至断裂。铸造模拟中预测的孔隙率已集成到拉伸测试的有限元模拟中。仿真和实验结果进行了比较，讨论和结论。一些标本表明在模拟和实验应力-应变行为上存在差异。然而，通过X射线成像以及通过比较模拟孔隙率和实际孔隙率，未发现孔隙度是造成这种分歧的原因。结论是，由于无效的热处理，铸件的质量受到了损害，应采用更加可控的方式进行热处理，以改善使用多型腔模具生产的铸件的质量和性能。