High Pressure Die Casting Workspace

HPDC Workspace

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

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