FLOW-3D CAST is a state-of-the-art metal casting simulation modeling platform that combines extraordinarily accurate modeling with versatility, ease of use, and high performance CLOUD computing capabilities. For every metal casting process, FLOW-3D CAST has a workspace ready to put you on a quick, intuitive path to modeling success. With 11 process workspaces, powerful post-processing, pioneering filling and solidification and defect analysis, FLOW-3D CAST delivers both the tools and roadmap for designing optimal casting solutions.
FLOW-3D CAST Playlist
This video demonstrates Active Simulation Control being used to increase data output frequency when fast shot begins so that flow details can be captured. Flux surfaces are placed at the gates to measure the average velocity. When the average velocity exceeds 35 m/s, Active Simulation Control sets the output frequency to 0.0007 seconds for the duration of the simulation.
This is a simulation of an automotive flywheel or bell housing, showing velocity contours of an aluminum alloy during a fast shot of a high pressure die casting process. It is part of a design phase to evaluate different gating options. Shown here is a comparison of five gates, simulating filling from a runner below the parting line to accomplish an 80-millisecond casting fill. The left-hand simulation in the video shows gates pointed upward below the parting line, while the right-hand simulation shows gates at the same location, angled at 45 degrees. Learn more at www.flow3d.com/cast.
This simulation represents the filling stage of a pipe casting manufactured using a horizontal centrifugal casting process. The pipe is cast with Chromium Molybdenum Steel GS 25CrMo4 and is 1 m long and 2.5 cm wall thickness.
The goal of casting pipes is to ensure that the thickness is uniform along its length. The cross-sectional view at the bottom of this video shows the distribution of the melt along its length. The melt should be uniformly distributed before solidification begins.
Simulation can be used to study the impact of the initial temperature of the mold, the pour temperature, and the pour rate on the solidification during fill. Another important process parameter is effect of the mold rotation rate (500 rpm in this case) on the distribution of melt along the mold length. If the mold rotates too slowly, the melt will not pick up speed quickly enough to keep it attached to the mold surface resulting in raining which can cause production to stop for a significant period of time while the mold and the shop floor is cleaned.
For more information about the Centrifugal Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/centrifugal-casting-workspace/
The goal of this simulation is to determine the cooling required to maintain a stable solidification profile during the continuous casting of Aluminum A356 plates. Melt is introduced into the process through a calcium silicate nozzle. Copper-Cobalt-Beryllium molds on both sides of the melt contain cooling channels to draw heat from the melt. The solidifying plate is drawn from the mold at a rate of 8 mm/sec. For more information about the Continuous Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/continuous-casting-workspace/
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.
FLOW-3D CAST‘s defect tracking capabilities help casting engineers predict where surface oxide defects are most likely to occur from the filling process. Oxides form due to an exposed molten metal surface to air and can end up in the part in undesirable locations. The final location of the defects depends on the overall flow conditions, turbulent mixing, fluid jetting and impingement. FLOW-3D CAST accurately tracks these oxides and their final locations to help improve designs. For more information about the High Pressure Die Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/high-pressure-die-casting-workspace/
The Investment Casting Process Workspace in FLOW-3D CAST v5.1 offers automatic shell generation in addition to advanced radiation modeling, in order to deliver extraordinary accuracy to aid the design modeling process. For more information about the Investment Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/investment-casting-workspace/
