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FLOW-3D Cast Validations
- HPDC: Flow Pattern
- Foundry: Flow Fill Pattern
- Air Entrainment
- Simulation vs. Short Shot
- Lost Foam Filling
- Die Erosion
- HPDC Filling
- HPDC Validation Showing Air Entrapment Defects
HPDC: Flow Pattern
Short shot compared to simulation results show good correlation. Courtesy of Littler Diecast.
Foundry: Simulating a Flow Fill Pattern
Side-by-side comparison of X-ray fill and a FLOW-3D filling
simulation. Three-dimensional gravity filling of a sand mold with
A356 aluminum alloy. The color is metal pressure. Simulation results
are shown in the vertical plane of symmetry. X-rays courtesy of
“Modeling of Casting, Welding, and Advanced Solidification Processes
VII, London, 1995.
Modeling Air Entrainment
X-ray validation of an oil filter housing for a diesel engine, 380 die cast alloy.
Results are colored by percent of entrained air. The detailed area in the X-ray
shows the maximum porosity concentration.
Simulation vs. Short Shot
From left to right: A transmission housing, an oil pan and an auto part
Predicting Lost Foam Filling
Comparison of real time X-ray and FLOW-3D Cast metal flow
simulation results on a lost foam L850 Block Bulkhead Slice.
Image courtesy of GM Powertrain.
Predicting Die Erosion
The area of die erosion due to cavitation was
correctly located in a comparison of
FLOW-3D Cast results to a real-world case.
Validating a HPDC Filling
Short shot HPDC casting validation
HPDC Validation Showing Air Entrapment Defects
This customer validation courtesy of Antrametal shows a comparison of simulation to experimental results using FLOW-3D's Air Entrapment model. It is an HPDC casting of a front cover to an electric motor for a washing machine. The air-related defects are shown qualitatively in the coloring of the image. Physical air pockets captured by other numerical capabilities within FLOW-3D are also clearly represented.
