Low Pressure Sand Casting Workspace

Workspace Highlights

    • Integration of sand properties including permeability, core gas and moisture content
    • Full process modeling includes void, venting and back-pressure effects
    • Advanced dynamics include post-fill solidification tilt motion

Workspace Overview

The Low Pressure Sand Casting (LPSC) Workspace provides an easy-to-use tool for simulating all the processes commonly used in the foundry. With the new LPSC Workspace, users have the tools they need to model and optimize their process parameters. Filters can be inserted into the bottom fill sprues to further control the fill patterns and eliminate impurities in the melt. FLOW-3D CAST provides ceramic filters for modeling their impact on the flow during filling. The LPSC Workspace provides exothermic riser assemblies and insulating sleeves to address shrinkage and porosity in the solidifying casting. Using FLOW-3D CAST’s roto-tilt feature, the mold can be flipped upside down prior to solidification so that the filling sprues can act as risers. This approach can eliminate the need for additional risering if the filling sprues are appropriately designed. 

Processes modeled

  • Pressure or velocity-controlled bottom feeding
  • Roto-tilt solidification

Flexible Meshing

  • Structured meshes for fast, easy generation
  • Multi-block meshes for localized accuracy control
  • Casting-conforming meshes for memory optimization

mold modeling

  • Permeable molds with gas and moisture release
  • Chills for localized cooling
  • Porous and standard inserts
  • Ceramic filters
  • Air vents

Advanced solidification

  • Chemistry-based solidification
  • Dimensionless Niyama criteria
  • Cooling rates, SDAS, grain size mechanical properties

Riser Tools

  • Exothermic riser database
  • Exothermic and insulating sleeves

Filling Accuracy

  • Gas/bubble entrapment
  • Surface oxide formation
  • Automatic drag calculation in filters

Mold Motion Control

  • Time-controlled mold rotation

Defect prediction

  • Porosity prediction
  • Shrinkage
  • Hot spots

Dynamic simulation control

  • Probe-controlled filling rates

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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