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High Pressure Die Casting Workspace Highlights
- Extraordinary fill accuracy
- Full process modeling includes advanced venting, PQ2, and spray cooling
- Dynamic simulation control allows dynamic runtime process control
- State-of-the-art aluminum silicon alloy solidification
The High Pressure Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model high pressure die casting applications with FLOW-3D CAST. Full control of shot sleeve motion, combined with advanced die thermal control, machine parameter modeling, and accurate resolution of fill and backpressure conditions make FLOW-3D CAST v5.1 the reference solution for the most demanding HPDC simulation needs. In addition to advanced porosity prediction and post-processing functionalities, the HPDC Workspace includes a state-of-the-art chemistry-based solidification and material strength model for Al-Si and Al-Cu based alloys.
Processes modeled
- High pressure die casting
Flexible Meshing
- FAVOR™ simple mesh generation tool
- Multi-block meshing
- Nested meshing
Die thermal managment
- Thermal die cycling
- Heat saturation
- Full heat transfer modeling
- Smart cooling channel control
- Spray cooling path modeling
Advanced solidification
- Porosity prediction
- Shrinkage
- Hot spots identification
- Mechanical property prediction
- Microstructure prediction
Ladle Motion
- 6 degrees of freedom motion definition
Vacuum and Venting
- Interactive probe placement
- Area and loss coefficient calculator
Filling Accuracy
- Slow and fast shot modeling
- Intensification pressure effects
- Gas and bubble entrapment
- Surface oxide calculation
- RNG and LES turbulence models
- Back pressure
Defect prediction
- Macro and micro porosity
- Gas porosity
- Early solidification
- Oxide formation
- Surface defect analysis
Surface Defect Analysis
- PQ2 analysis
- Probe based triggers
- Heat controls
- Vacuum and venting controls
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
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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