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 Cast’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 Cast 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
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.
HPDC: Flow Pattern
Short shot compared to simulation results show good correlation. Courtesy of Littler Diecast Corporation.
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.
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.
Simulation vs. Short Shot
Validating a High Pressure Die Casting Filling
Predicting Die Erosion
Core Drying Validation
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.