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Investment casting workspace

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Investment Casting Workspace Highlights

  • Full process modeling for investment casting processes
  • Streamlined shell creation from casting pattern
  • Advanced radiation model captures full radiative heat transfer between shell surfaces
  • Advanced motion controls include Bridgman, ladle and spin dynamics

Workspace Overview

The Investment Casting Workspace provides investment casters with an easy-to-use tool for simulating all aspects of investment casting, including shell generation, filling, solidification (with either static or moving Bridgman shell molds), and cooling. A shell mold creation tool is provided for quick and reliable shell geometry creation, while radiation and view factor models accurately capture radiative heat transfer between different parts of the shell. For directional solidification, a moving oven with a hot upper section separated from a cooler lower section captures the Bridgman process. Melt surface evolution as well as mold motion, filling detail and solidification patterns are readily assessed through intuitive post-processing tools, allowing for process modifications to be implemented with confidence.

Investment Casting Playlist

7 Videos
Description
Description

This FLOW-3D CAST filling simulation of an investment casting is used to assess the oxide formation, air entrainment, and heat transfer to the shell.

Processes modeled

  • Filling
  • Solidification – Static and Bridgman
  • Cooling
    •

Shell mold creation

Thermal mold modeling

  • Full radiation modeling with view factors
  • Convection and conduction heat transfer
    •

Multi-block meshing

Extraordinary accuracy in filling simulations

  • Gas/bubble entrapment
  • Surface oxide calculation
  • RNG and LES turbulence models
    •

Ladle Pouring

Advanced solidification

  • Porosity prediction
  • Shrinkage
  • Directional solidification
    •

Defect prediction

  • Porosity prediction
  • Entrained air
  • Early solidification
  • Oxide formation
    •

Dynamic simulation control

  • Pour control based on flow dynamics
    •

Complete analysis package

  • Animations with multi-viewports - 3D, 2D, history plots, volume rendering
  • Porosity analysis tool
  • Side-by-side simulation results comparison
  • Sensors for measuring melt temperature, solid fraction
  • Particle tracers
  • Batch post-processing
  • Report generation
    •

Explore Process Workspaces

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Proud to be Corporate Members

NADCA Corporate Member
AFS corporate member
We recently went from a drawing on a napkin to the geometry created and simulation running within 8 hours. I don’t know exactly what it was like before we started using FLOW-3D CAST, but it takes 6 to 7 weeks minimum for tooling design changes to be made by our pattern maker. Take multiples of that, plus more depending on the part and how many design iterations it would take to get a good pattern. With FLOW-3D CAST, we usually get it right on the first try now. It’s huge for our business.
Steven KingDesign Engineer, Omega Castings, Inc.
FLOW-3D CAST has been a tremendous asset to our quality program. After having evaluated six different casting simulation software Howell Foundry made the decision to purchase FLOW-3D CAST. Some of the factors in this decision include its setup versatility, cost, and most importantly its accuracy of the simulation to reality. FLOW-3D CAST’s powerful simulation ability coupled with its updated results viewer has been especially helpful on our most complex jobs to make sure we have a quality casting on the first pour.
Joe HuttoVice President of Operations, Howell Foundry
At 4C-Technologies we have been pioneers in using various software flow simulation solutions for nearly 35 years. We optimize part designs and tool/runner designs on casted HPDC parts in various metal alloys. Since 2008 we have solely been using FLOW-3D CAST as it turned out to give by far the best accuracy. Furthermore, the support from the FLOW-3D CAST team is outstanding.
Lars F. Hansen4C-Technologies
I have personally modeled the filling, solidification, and cooling of countless castings, with the goal being to maximize metal cleanliness and soundness, and to control grain structure, segregation and stress related defects. We have had a great deal of success using FLOW-3D CAST to predict casting performance, to optimize quality, and to reduce cost by reducing rework, scrap, and lead-time.
Richard EmmerichSr. Metallurgical Dev't Engineer, MetalTek International
We are using FLOW-3D CAST not only as a die cast process simulation tool but also as a general CFD software tool. If during die cast process development, any part design changes need to be recommended to a customer, FLOW-3D CAST allows us quickly and reliably evaluate part design changes, and present to a customer not only the proposed changes but also the effects those changes will have on the part performance.
Alex ReikherShiloh Industries
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FLOW-3D CAST Webinar

V8 Engine Block Sand Casting: Design Exploration of Runners, Risers and Chills through Flow and Solidification Simulations

Thursday, April 18th at 1:00 p.m. ET

A V8 engine block is a complex casting with several thick and thin-walled features. A large volume of metal alloy needs to be poured well to fill the entire casting and compensate for shrinkage of metal, eliminating defects and porosity in critical and stress tested areas of an engine block’s life cycle. This webinar aims to show an exploratory design process starting with the engine block thermal solidification analysis and various factors involved in designing a casting feeding and riser system.

Register now

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