Sand Casting 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.
Sand Casting Playlist
This FLOW-3D CAST simulation shows the thermal activation of an exothermic riser sleeve and the consequent feeding of the casting. For more information about the Gravity Die Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/gravity-die-casting-workspace/
A full gravity sand casting analysis with filling, solidification and cooling, where the mold has filters and insulated risers. This simulation is part of a webinar on sand asting design strategies with FLOW-3D CAST. For more information about the Sand Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/sand-casting-workspace/
This FLOW-3D CAST filling simulation of a turbo housing is used to understand oxide formation in the metal front. For more information about the Sand Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/sand-casting-workspace/
This filling simulation of a green sand casting is used to understand the flow pattern of a stepped gating system for a V8 crankshaft. For more information about the Sand Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/sand-casting-workspace/
This preliminary solidification simulation of a green sand casting is used to understand the solidification path inherent within a part. This type of simulation informs rigging design. For more information about the Sand Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/sand-casting-workspace/
This FLOW-3D CAST gravity die casting simulation shows the thermal activation of an exothermic riser sleeve. For more information about the Gravity Die Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/gravity-die-casting-workspace/
This simulation looks at the dynamics of a bottom gated castings. The mold is filled from two pouring diametrically opposed pouring basins. The analysis is used to see the behavior of the two metal fronts and the effect it has on defect propagation. For more information about the Sand Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/sand-casting-workspace/
This simulation illustrates the filling and solidification of ductile cast iron crankshafts, which was used to investigate a directional solidification into the risers. FLOW-3D CAST can be used to predict and avoid casting defects. Accounting for factors in cast iron including carbon expansion, primary (open) shrinkage cavities and secondary (internal) shrinkage cavities can be reliably displayed. Based on the size and position of the defects, the necessity of improvements to the casting design can be determined.
This simulation shows the filling of a planetary carrier with a ladle. The complete process from filling to solidification can be simulated with FLOW-3D CAST, including chills and exothermic risers, allowing for accurate prediction of casting defects and ensuring the best possible casting design.
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
Explore Process Workspaces
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