Prototypes used to be made to detect errors; now this is done using 3D casting simulation. This saves you considerable time and money. The casting process and the cast piece can be optimised well using simulation software. It improves quality and reduces production costs considerably.
If our engineers can be involved in the design process early, our specific knowledge of casting and coagulation simulations can provide you with huge benefits. So when tendering a cast piece, do not choose simply the lowest price, but evaluate the quality that can be offered as well. Bit Holder. Chisel Plate Holder. Tying Hook. The mold, made of H13 steel, is preheated to 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. This simulation represents the filling stage of a pipe casting manufactured using a horizontal centrifugal casting process. The goal of casting pipes is to ensure that the thickness is uniform along its length. The cross-sectional view at the bottom of this video shows the distribution of the melt along its length.
The melt should be uniformly distributed before solidification begins. Simulation can be used to study the impact of the initial temperature of the mold, the pour temperature, and the pour rate on the solidification during fill. Another important process parameter is effect of the mold rotation rate rpm in this case on the distribution of melt along the mold length. If the mold rotates too slowly, the melt will not pick up speed quickly enough to keep it attached to the mold surface resulting in raining which can cause production to stop for a significant period of time while the mold and the shop floor is cleaned.
An important process parameter for controlling air entrainment in HPDC is the velocity profile of the shot plunger. Additionally, a slow shot velocity profile calculator is included which helps to quickly estimate the best shot profile for minimizing air entrainment. A global view of total entrained air is available as well as user-specified sampling volumes which allow local casting regions to be analyzed. When designing the gating for an HPDC die, it is useful to understand the contribution of each gate to the overall filling pattern of the casting.
Ideally, a well balanced filling with each gate filling the casting without significant cross flow will result in the best quality casting. Because of the high velocities and accompanying low pressures created in HPDC processes, cavitation is possible. Cavitation bubbles collapsing on the die surface can create pitting which in turn causes surface quality issues on the casting as well as drastically shortening the life of expensive dies.
Rather than providing instantaneous indications of cavitation, which are not necessarily problematic, the cavitation potential model provides an overall estimation of the potential for cavitation damage by integrating the duration of the cavitation at each location on the die surface over the fill time.
Maintaining a melt temperature above the liquidus temperature is important in HPDC processes to prevent cold shuts and other defects.
With accurate filling simulations at their disposal, casting process engineers can identify pour temperature and die temperature profiles that minimize early solidification issues in designs. This video shows the use of history probes placed in the gates to gain insight into the flow balance between gates. This information is very helpful, especially in multi-cavity castings where the flow between casting cavities varies.
This FLOW-3D CAST filling simulation of a complex thin walled part shows the air entrainment variable to understand where defects can become an issue in the filling process. Visualization of air entrainment can be used to understand die venting, back-pressure, and areas of porosity.
This FLOW-3D CAST filling simulation of an automotive component visualizes the oxide formation variable to understand where defects can become an issue in the filling process. The mold is spun about its vertical axis at rpm, providing an outward acceleration of g at the surface of the mold. The left frame shows the pickup of the melt by the mold and helps determine the rate at which the melt distributes vertically over time.
The upper right frame shows the solid fraction in the melt; this analysis helps determine the proper mold preheat to avoid premature solidification. In the lower right frame, the entrained air mass concentration is shown. As long as solidification does not occur prior to complete filling, all of the entrained air will be forced to the inner diameter of the casting, to be machined off later.
The goal of this simulation is to determine the cooling required to maintain a stable solidification profile during the continuous casting of Aluminum A plates. Melt is introduced into the process through a calcium silicate nozzle. Copper-Cobalt-Beryllium molds on both sides of the melt contain cooling channels to draw heat from the melt.
This centrifugal casting filling simulation with non-intertial reference frames allows the user to view the fluid front in the rotating mold. Simulation courtesy of Simulated Engineering. Simulation courtesy of XC Engineering. Investment Casting Workspace.
Featuring a fast and accurate shell mold generation tool and full radiation model. Easy-to-use tool for modeling the shooting and hardening of sand cores. High Pressure Die Casting Workspace. An intuitive modeling environment designed to help engineers model HPDC applications. 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.
Contact Sales sales flow3d. 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.
Richard Emmerich Sr. 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. Alex Reikher Shiloh Industries. Centrifugal Casting.
Continuous Casting. Gravity Die Casting. High Pressure Die Casting. Investment Casting. Lost Foam Casting. Low Pressure Die Casting. Low Pressure Sand Casting. September 29, - September 30, The Marlborough DesignPart Show, featuring over exhibiting companies, is the largest and longest-running design and contract manufacturing show in the Northeast.
Efficient casting development, safe starts of production and robust production windows are the EN ES. EN TR. EN ZH. EN KO. Toggle navigation.
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