Gravity Die Casting Workspace

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.

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

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.

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.

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