Tilt Pour Casting Workspace Highlights
- Advanced die motion control
- State-of-the-art die thermal management, dynamic cooling channels, spray cooling, thermal cycling
- Advanced flow solutions deliver accurate gas entrapment porosity
Workspace Overview
The Tilt Pour Casting Workspace is an intuitive modeling environment designed to help engineers successfully model tilt pour casting applications with FLOW-3D CAST. The workspace includes process-specific die and material types, where rotational motions are easily defined in order to match exact machine capabilities. Venting and backpressure are included in the fill analysis for a complete analysis of air entrapment defects, while thermal die cycling and state-of-the-art solidification models are seamlessly connected to the fill through the workspace’s sub-process architecture. The Tilt Pour Casting Workspace provides a complete and accurate solution for all aspects of the simulation in a simple yet versatile modeling environment.
Tilt Pour Casting Playlist
In this FLOW-3D CAST simulation of an 8-cavity tilt pour casting, A356 aluminum is poured at 738 C by rotating the mold from a horizontal orientation to a vertical orientation over 18 seconds. The H13 steel mold is thermally prepared by simulating 5 cycles of fill/solidify/spray cooling using FLOW-3D CAST’s thermal die cycling model. For more information about the Tilt Pour Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/tilt-pour-casting-workspace/
This tilt pour filling simulation of an aluminum ornament mold is used to identify defect areas in the metal front. The tilt profile and trapped air can also be seen in this analysis. This example is part of a webinar on FLOW-3D CAST’s Tilt Pour Casting Workspace. Watch it on-demand at: https://www.flow3d.com/resources/webinars/. For more information about the Tilt Pour Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/tilt-pour-casting-workspace/
This FLOW-3D CAST thermal die cycling simulation is used to assess the thermal saturation over multiple cycles. For more information about the Tilt Pour Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/tilt-pour-casting-workspace/
In this tilt pour casting of an aluminum ornamental fixture, the ladle is preheated to 500 C and is filled with Aluminum A356 at 708 C. The mold, made of H13 steel, is preheated to 200 C. The mold and ladle are rotated from horizontal to about 15 degrees from vertical allowing the melt to flow in a controlled fashion into the mold cavities. Air vents are placed on the mold cavities to allow air to escape. This simulation shows the temperature distribution in the melt and the solid fraction evolution as the mold cavities fill. For more information about the Tilt Pour Casting Workspace, visit https://www.flow3d.com/products/flow-3d-cast/tilt-pour-casting-workspace/
FLOW-3D CAST can be used to simulate any tilt casting process with a high degree of realism and accuracy. While turbulence and air entrapment in the molten metal can pose a challenge to successful castings, even the smallest air bubbles that occur during the course of a filling process can be reliably predicted and tracked with FLOW-3D CAST. Changes to the casting process or mold design can be tested in subsequent simulations to ultimately produce the best possible component quality.
Processes modeled
- Tilt pour
- Reverse tilt pour
Flexible Meshing
- FAVOR™ simple mesh generation tool
- Multi-block meshing
- Conforming meshing
Die thermal managment
- Thermal die cycling
- Heat saturation
- Full heat transfer modeling
Advanced solidification
- Porosity prediction
- Shrinkage
- Hot spots identification
- Thermal modulus
- Mechanical property prediction
Sand Cores
- Core gas evolution
- Material definitions for core properties
Mold Motion Control
- Six axes of rotation
- Tabular input for rotational velocities
Defect prediction
- Macro and micro porosity
- Gas porosity
- Early solidification
- Oxide formation
- Surface defect analysis
Dynamic simulation control
- Event probe-based triggers for motion control
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
