Solving the World’s Toughest CFD Problems

Simulation of Joule Heating-based Core Drying

Joule heating-based core drying

The new, patented Advanced Core Solution (ACS) process aims for time- and energy-efficient core drying and curing. The ACS process uses a property common to all inorganic binder systems: because they are water-based, they are electrically conductive.

Investigation of Mould Leakages in a Gravity Casting

CM Tarrico Case Study

Mould design is a complex undertaking that must consider not only fluid dynamics and metal solidification patterns, but problems that may arise from the mould itself and how it reacts to stresses from heat transfer. In this case study, CM Taricco, a mould maker company based in Italy, discusses how they solved the problem of metal leakages at the bottom of one of their new moulds.

Increasing Productivity by Reducing Ejection Times

Hellebusch Tool and Die Case Study

In high pressure die casting, simulation software is used to help design better gating systems to feed the metal into the casting, improve the timing of the shot sleeve tip to prevent air entrainment due to turbulence, and identify the most effective locations for overflows, among other things. In this article, we will look at how to reduce the time before a part can be ejected from the die in order to reduce the process time.

Detecting Porosity with the Core Gas Model

GM Graham White Manufacturing Case Study

One casting defect that has yet to be thoroughly addressed is the common core gas blow defect. The physics of this problem involves a complicated interaction between the metal, core and binder. Failure to solve it can result in high scrap levels. Read about how GM Powertrain and Graham-White Manufacturing Co. addressed core gas defects with FLOW-3D CAST.

Improving High Pressure Die Casting Designs

Littler Die Cast Case Study

Littler Diecast was able to demonstrate that they could pinpoint the defects through simulation without previous knowledge of the problems. This impressed the client enough to land them the job.

Realizing Da Vinci’s Il Cavallo

Da Vinci Case Study

In the late 15th century, Leonardo Da Vinci spent 17 years devising a plan to cast a 24-ft. tall bronze horse—the largest equestrian statue in the world—in a single pour.

Aluminum Integral Foam Molding Process

Foam molding - FLOW-3D CAST case study

Researchers from the University of Erlangen-Nurember concluded that FLOW-3D CAST is an important instrument to investigate potential weak points in the fabrication of new integral foam parts before their actual production. In that way, a successful filling and blowing agent distribution without cold flow or dead zones can be assured.

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