High Pressure Die Casting Workspace

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

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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