Solving the World’s Toughest CFD Problems

Gravity Die Casting Workspace Highlights

    • State-of-the-art die thermal management, dynamic cooling channels, spray cooling, and thermal cycling
    • Ladle pour with dynamic ladle motion based on pouring cup fill condition
    • Advanced flow solutions deliver accurate gas entrapment & gas porosity

Workspace Overview

The Gravity Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model gravity die casting applications with FLOW-3D CAST. Ladle motion, venting and backpressure are included in the fill analysis for an accurate prediction of air entrapment and porosity defects, while die thermal management and state-of-the-art solidification models seamlessly connect to the fill solution through the workspace’s sub-process architecture. The Gravity Die Casting Workspace provides a complete and accurate solution for all aspects of the simulation in a simple, versatile modeling environment.

Description

Learn about the modeling versatility of FLOW-3D CAST in our latest webinar: Advanced Metal Casting Simulation, which is now available to watch on demand at: https://www.flow3d.com/resources/webinars/
Video courtesy of BMW and Flow Science Deutschland.

Processes modeled

  • Gravity die casting
  • Vacuum die casting

Flexible Meshing

  • FAVOR™ simple mesh generation tool
  • Multi-block meshing
  • Nested meshing

Mold modeling

  • Localized die heating elements and cooling channels
  • Spray cooling of the die surface
  • Ceramic filters
  • Air vents

Advanced solidification

  • Porosity
  • Shrinkage
  • Hot spots
  • Mechanical property
  • Microstructure

Sand Cores

  • Core gas evolution
  • Material definitions for core properties

Die Thermal Management

  • Thermal die cycling
  • Heat saturation
  • Full heat transfer

Ladle Motion

  • 6 degrees of freedom motion definition

Defect prediction

  • Macro and micro porosity
  • Gas porosity
  • Early solidification
  • Oxide formation
  • Surface defect analysis

Vacuum and Venting

  • Interactive probe placement
  • Area and loss coefficient calculator

Macro and Micro Porosity

  • Gas porosity
  • Early solidification
  • Oxide formation
  • Surface defect analysis

Filling Accuracy

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

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

Proud to be Corporate Members

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.

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