Sand Casting Workspace

Workspace Highlights

  • Integration of sand properties include permeability, core gas and moisture content
  • Ladle pour with dynamic ladle motion based on pouring cup fill condition
  • Advanced flow solutions deliver accurate gas entrapment and porosity

Workspace Overview

The Sand Casting Workspace provides sand casters with all the tools needed to simulate their filling, solidification, and cooling analyses. The Sand Casting Process Workspace provides the user with a templated design tailored to deliver a clean, easy-to-use setup interface that speaks the language of the casting process engineer. 

Defects in sand castings can often be traced back to the filling stage. FLOW-3D CAST’s extraordinary accuracy in predicting metal flow provides insight into the performance of the rigging system and resulting fill defects. Oxide formation and cold shuts are accurately tracked and located in the final casting. Risers are sized and placed at hot spots while advanced solidification and shrinkage analysis allow for a final, optimized design to be reached in even the most challenging manufacturing environments.

Processes modeled

  • Filling
  • Solidification
  • Cooling

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

Filling Accuracy

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

Core Modeling

  • Sand cores with gas generation
  • Salt cores

Defect prediction

  • Entrained air
  • Oxide formation and tracking
  • Cold shuts
  • Porosity prediction
  • Shrinkage
  • Hot spots

Riser Tools

  • Exothermic riser assemblies
  • Insulating and exothermic sleeves

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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