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Modeling Moving Casting Parts with FLOW-3D Cast

Shot Sleeves and Ladle Pours

The General Moving Object model, the only one of its kind in commercial CFD software, allows users to model rigid body dynamics with six-degrees-of-freedom fully coupled with fluid flow. This fluid structure interaction model give casters a powerful tool, including the following capabilities:

Related links:

Casting Processes with Changing Geometry

Modeling Moving Engine Parts Using the FLOW-3D GMO Model

Modeling Casting on the Move

Clean Steel Casting Production - Evaluation of Laboratory Settings

Casting Simulation: How well do reality and virtual casting match?

Below are examples of how FLOW-3D Cast's fluid structure interaction capabilities can be applied to casting design issues.

Ladle Pouring

This FLOW-3D Cast simulation shows temperature contours during metal pouring process using a ladle. This is essential to accurately calculate filling with precise foundry flow rate in the sprue and through the runner. FLOW-3D Cast also captures accurate back pressure in the runner and sprue system to match the foundry fill time.

Shot Sleeve Simulation

Shot sleeve driving fluid through the runners and gating system to fill a tree structure of parts.

Ladle Pour and Shot Sleeve Simulation

A ladle filled with hot metal moves forward to fill a shot sleeve, and then the motion of the shot sleeve drives the metal into a die.

Gravity Cast Ladle Pour

Filling of a cylinder head using FLOW-3D's GMO model
Simulation of a cylinder head for a 3.6L V6 engine, used in the Cadillac CTS and Saturn Aura XR colored by defect concentration. It is cast with an A319 alloy using a semi-permanent mold process. The Air Entrainment and Surface Defect models in FLOW-3D Cast were used to optimize the basin and ladle design. Image courtesy of General Motors Powertrain.

Gravity Cast Example

A gravity casting example using FLOW-3D. A moving cup pours the metal inside the mold, used for a realistic representation of the casting process. Simulation results courtesy of Teksid.

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