Investment Casting Workspace

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Investment Casting Workspace Highlights

Full process modeling for investment casting processes
Streamlined shell creation from casting pattern
Advanced radiation model captures full radiative heat transfer between shell surfaces
Advanced motion controls include Bridgman, ladle and spin dynamics

Workspace Overview

The Investment Casting Workspace provides investment casters with an easy-to-use tool for simulating all aspects of investment casting, including shell generation, filling, solidification (with either static or moving Bridgman shell molds), and cooling. A shell mold creation tool is provided for quick and reliable shell geometry creation, while radiation and view factor models accurately capture radiative heat transfer between different parts of the shell. For directional solidification, a moving oven with a hot upper section separated from a cooler lower section captures the Bridgman process. Melt surface evolution as well as mold motion, filling detail and solidification patterns are readily assessed through intuitive post-processing tools, allowing for process modifications to be implemented with confidence.

Investment Casting Playlist

7 Videos

Investment Casting Filling Analysis | FLOW-3D CAST

0:10

Turbine Blade Investment Casting Simulation | FLOW-3D CAST

0:21

Investment Casting Filling Comparison | FLOW-3D CAST

0:19

Investment Casting Solidification Comparison | FLOW-3D CAST

0:24

FLOW-3D CAST Investment Casting Process Workspace fill example

0:27

FLOW-3D CAST Investment Casting Process Workspace solidification and porosity example

0:20

Multi Cavity Investment Casting | FLOW-3D CAST

0:18

Description

Description

This FLOW-3D CAST filling simulation of an investment casting is used to assess the oxide formation, air entrainment, and heat transfer to the shell. For more information about the Investment Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/investment-casting-workspace/

Processes modeled

Filling

Solidification – Static and Bridgman

Cooling

Shell mold creation

Thermal mold modeling

Full radiation modeling with view factors

Convection and conduction heat transfer

Multi-block meshing

Extraordinary accuracy in filling simulations

Gas/bubble entrapment

Surface oxide calculation

RNG and LES turbulence models

Ladle Pouring

Advanced solidification

Porosity prediction

Shrinkage

Directional solidification

Defect prediction

Porosity prediction

Entrained air

Early solidification

Oxide formation

Dynamic simulation control

Pour control based on flow dynamics

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

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Proud to be Corporate Members

FLOW-3D CAST has been a tremendous asset to our quality program. After having evaluated six different casting simulation software Howell Foundry made the decision to purchase FLOW-3D CAST. Some of the factors in this decision include its setup versatility, cost, and most importantly its accuracy of the simulation to reality. FLOW-3D CAST’s powerful simulation ability coupled with its updated results viewer has been especially helpful on our most complex jobs to make sure we have a quality casting on the first pour.

At 4C-Technologies we have been pioneers in using various software flow simulation solutions for nearly 35 years. We optimize part designs and tool/runner designs on casted HPDC parts in various metal alloys. Since 2008 we have solely been using FLOW-3D as it turned out to give by far the best accuracy. Furthermore, the support from the FLOW-3D team is outstanding.

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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