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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.
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
Proud to be Corporate Members


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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