Casting simulation software cuts energy use and waste generation in half

Caterpillar Inc.
Peoria, IL

Argonne and Caterpillar (Peoria, Ill.) have developed the Casting Process Simulator (CaPS) for use in Caterpillar's foundry processes. Caterpillar used CaPS to perform more than 300 simulations of the casting process for more than 70 parts. By using CaPS, Caterpillar was able to improve the mold geometry to allow more rapid and uniform filling by the molten metal. These improvements led to higher-quality castings with extremely low rejection rates. In addition to quality improvements, the new simulation program has provided environmental benefits as well. Using the new simulation, Caterpillar can achieve savings in raw materials used in the casting process. For example, each ton of iron cast requires a ton of sand in the smelting process. A large part of this sand mixture becomes a waste product that is eventually sent to a landfill. Employing the CaPS simulation has, for specific applications, allowed casting of two parts in the same volume of mold where previously only one part could be poured. This effectively cuts energy consumption and waste generation in half for that part.

Using the Casting Process Simulator (CaPS), Caterpillar performed more than 300 simulations of the casting process for more than 70 of its parts. The company was able to improve the mold geometry to allow more rapid and uniform filling by the molten metal, as represented in these simulations. The improvements led to better castings and less waste generation.

Argonne's work was supported by the U.S. Department of Energy's Laboratory Technology Research Program, Office of Energy Research.

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