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.
Gravity Die Casting Playlist
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.
This FLOW-3D CAST simulation of a thermal die cycling of a gravity die cast mold is used to understand the thermal distribution in the mold. This example is part of a webinar on FLOW-3D CAST’s Gravity Die Casting Workspace. For more information about the Gravity Die Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/gravity-die-casting-workspace/
This FLOW-3D CAST simulation demonstrates how the keyframing capability in FlowSight can be used to open the die halves “visually” during filling and display the solid temperature on the die faces while showing the metal filling the dies. This simulation courtesy of CM Tarrico, is used to understand propagation of the metal front, as well as thermal distribution in the mold. Learn more at https://www.flow3d.com/cast
Deformation of the mould during die cyclings, simulated using the Fluid Structure Interaction model in FLOW-3D CAST. Deformations are amplified x20. Results postprocessed with FlowSight, FLOW-3D CAST‘s state-of-the-art postprocessor. To learn more about this case study from CM Taricco, go to https://www.flow3d.com/investigation-of-mould-leakages-in-a-gravity-casting
Simulation of the mould’s temperature during the die cyclings using FLOW-3D CAST. Results postprocessed with FlowSight, FLOW-3D‘s state-of-the-art postprocessor. To learn more about this case study from CM Taricco, go to http://www.flow3d.com/investigation-of-mould-leakages-in-a-gravity-casting
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
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