Casting Validations

View metal casting validations from FLOW-3D and FLOW-3D Cast customers around the world who use simulation software to constantly improve their designs and manufacturing processes.

Ladle Pour Simulation

Optimizing your shot sleeve process is essential to ensuring quality parts. This comparison between FLOW-3D’s simulation results and a real-world case highlights how using simulation can help engineers improve designs before manufacturing expensive tooling. With the moving object model, FLOW-3D is able to accurately capture the fluid motion throughout the process, giving engineers insight from the actual ladle pour to the fast shot. Simulation courtesy of Mr. Antoni Drys from Nemak Poland Sp. z o.o

Gravity Casting Validation

A gravity casting simulation compared with the reconstruction of the real filling, based on thermocoupled data. Courtesy of XC Engineering and Peugeot PSA.

Foundry: Simulating a Flow Fill Pattern

Side-by-side comparison of X-ray fill and a FLOW-3D Cast 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.

X-ray validation of a sand mold filling

X-ray validation of a sand mold filling

HPDC: Flow Pattern

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

Short sleeve validation - simulation versus casting part

Short sleeve validation – simulation versus casting part

HPDC Validation Showing Air Entrapment Defects

This customer validation courtesy of Antrametal shows a comparison of simulation to experimental results using FLOW-3D Cast‘s Air Entrapment model. It is an HPDC 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 Cast are also clearly represented.

HPDC validation by Antrametal

Successful comparison of casting simulation versus experimental results courtesy of Antrametal.

Modeling Air Entrapment

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.

Metal casting defect validation

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

Simulation vs. Short Shot

Simulation validation of a short shot

Validation snapshots of actual casting parts vs. FLOW-3D Cast simulations. From left to right: A transmission housing, an oil pan and an auto part.

Validating a High Pressure Die Casting Filling

Short shop high pressure die casting validation

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

Predicting Die Erosion

Die erosion validation

The area of die erosion due to cavitation was correctly located in a comparison of FLOW-3D Cast results to a real-world case.

Core Drying Validation

BMW core drying simulation

A comparison made by BMW between simulation and experiment of the drying of an inorganic core.

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.