Low Pressure Die Casting Workspace

Low Pressure Die Casting Workspace Highlights

- Pressure controlled filling for absolute fill accuracy
- Full process modeling includes void, venting and back-pressure effects
- Advanced solidification and heat transfer control for precise early freezing and solidification defects like porosity

Workspace Overview

The Low Pressure Die Casting Workspace is an intuitive modeling environment designed for engineers to successfully model low pressure die casting applications with FLOW-3D CAST. Flexible pressure controls allow engineers to accurately reproduce pressure, venting and backpressure conditions in order to deliver a complete analysis of fill, air entrapment and porosity defects. Die thermal management and state-of-the-art solidification models seamlessly connect to the fill through the workspace’s sub-process architecture. The Low Pressure Die Casting Workspace provides a complete and accurate solution for all aspects of the simulation in a simple yet versatile modeling environment.

Processes modeled

Gravity low 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

Advanced solidification

Porosity prediction

Shrinkage

Hot spots identification

Mechanical property prediction

Microstructure prediction

Sand Cores

Core gas evolution

Material definitions for core properties

Vacuum and Venting

Interactive probe placement

Area and loss coefficient calculator

Ladle Motion

6 degrees of freedom motion definition

Filling Accuracy

Gas and bubble entrapment

Surface oxide calculation

RNG and LES turbulence models

Backpressure

Defect prediction

Macro and micro porosity

Gas porosity

Early solidification

Oxide formation

Surface defect analysis

Dynamic simulation control

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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