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FLOW-3D Cast Validations

Gravity Casting Simulation

A gravity casting simulation compared with the reconstruction of the real filling, based on thermocoupled data. Simulation results are post-processed with FlowSight, coming soon in FLOW-3D v11. Courtesy of XC Engineering and Peugeot PSA.

HPDC: Flow Pattern

Short sleeve validation - simulation versus casting part.

Short shot compared to simulation results show good correlation. Courtesy of Littler Diecast.

Foundry: Simulating a Flow Fill Pattern

X-ray validation of a sand mold filling

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.

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.

Casting simulation validation of air entrapment
Successful comparison of casting simulation versus experimental results courtesy of Antrametal.

Modeling Air Entrainment

X-ray vs FLOW-3D CFD validation of an oil filter housing for a diesel engine.

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

Validation snapshots of actual casting parts vs FLOW-3D simulations

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. Simulation courtesy of GM Powertrain.

Predicting Die Erosion

Simulating realistic results for cavitation potential

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

HPDC casting validation comparing FLOW-3D results to the actual part

Short shot HPDC casting validation.