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:
- Users can evaluate the motion of multiple objects.
- There are no limitations on the geometry or range of motion.
- Objects can be allowed to move freely, or the user can prescribe the motion.
- Specified time-dependent thrust forces and torques can be applied to the objects.
- The range of motions includes motion around a fixed axis or point.
Below are examples of how FLOW-3D Cast's fluid structure interaction capabilities can be applied to casting design issues.
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
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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