OPTIMIZED CASTING DESIGNS
Cast provides metal casters with highly-accurate insights allowing you to explore design concepts quickly and efficiently. FLOW-3D
OPTIMIZE CASTING DESIGNS WITH HIGHLY-ACCURATE FILLING AND SOLIDIFICATION SIMULATIONS
Cover image courtesy of BMW Group
Cast is available in three configurations, depending on your modeling needs: BASIC, EXTENDED, ADVANCED .
FLOW-3D
OPTIMIZED WORKFLOWS DESIGN FLOW
POWERFUL SOLVER
Intuitive interface lets users set up highly-accurate simulations quickly and correctly.
Wide range of integrated physical models capable of modeling casting processes and providing solutions to filling and solidification defects.
CLEAR MODEL INPUT Top-down workflow ensures that all aspects of model setup are addressed. Models and parameters are defined using casting terminology.
FAST MESHING Meshing captures complex parts and molds with minimal user input. Casting designs can be imported and meshed in minutes.
MATERIAL DATABASE Material properties for alloys, molds, cores and filters. Customizable database with imported materials.
Cast is available in three configurations, depending on your modeling needs: BASIC, EXTENDED, ADVANCED .
FLOW-3D
OPTIMIZED WORKFLOWS DESIGN FLOW
POWERFUL SOLVER
Intuitive interface lets users set up highly-accurate simulations quickly and correctly.
Wide range of integrated physical models capable of modeling casting processes and providing solutions to filling and solidification defects.
CLEAR MODEL INPUT Top-down workflow ensures that all aspects of model setup are addressed. Models and parameters are defined using casting terminology.
FAST MESHING
MATERIAL DATABASE Material properties for alloys, molds, cores and filters. Customizable database with imported materials.
Meshing captures complex parts and molds with minimal user input. Casting designs can be imported and meshed in minutes.
STREAMLINED MESHING FOR COMPLEX PARTS FLOW-3D Cast’s unique meshing
methodology, FAVOR TM,
handles complex geometry within a structured mesh.
FAVOR allows FLOW-3D Cast to maintain highly-accurate flow calculations around complex geometries. This technique is referred to as free- gridding because
the mesh and geometry can be changed independently of each other, greatly simplifying the meshing process and saving significant time during simulation setup. REDUCE SETUP TIME WITH FAVOR™, OUR UNIQUE STREAMLINED MESHING METHODOLOGY
STREAMLINED MESHING FOR COMPLEX PARTS FLOW-3D Cast’s unique meshing
methodology, FAVOR TM,
handles complex geometry within a structured mesh.
FAVOR allows FLOW-3D Cast to maintain highly-accurate flow calculations around complex geometries. This technique is referred to as free- gridding because
the mesh and geometry can be changed independently of each other, greatly simplifying the meshing process and saving significant time during simulation setup. REDUCE SETUP TIME WITH FAVOR™, OUR UNIQUE STREAMLINED MESHING METHODOLOGY
POWERFUL VISUALIZATION FlowSight™, an integrated state-of-the-art postprocessor, offers powerful visualization for identifying casting defects.
• Portable results • Report generation • Batch postprocessing • Multiple iso-surfaces • 2D-slicing through results • Multiple views of simulation results • Simultaneous stress and uid ow view • Extensive annotation capabilities • Read and plot data from external sources • Interactive probing • Texture mapping • Defnable viewpoints • Volume rendering • Flipbook • Vent ow rates
POWERFUL VISUALIZATION FlowSight™, an integrated state-of-the-art postprocessor, offers powerful visualization for identifying casting defects.
• Portable results • Report generation • Batch postprocessing • Multiple iso-surfaces • 2D-slicing through results • Multiple views of simulation results • Simultaneous stress and uid ow view • Extensive annotation capabilities • Read and plot data from external sources • Interactive probing • Texture mapping • Defnable viewpoints • Volume rendering • Flipbook • Vent ow rates
DESIGN OPTIMIZATION
OXIDE FORMATION
AIR ENTRAINMENT
MICROPOROSITY
SOLIDIFICATION AND SHRINKAGE
THERMAL STRESS
FLOW-3D Cast ’s defect
The air entrainment model in FLOW-3D Cast is used to estimate the amount of entrained air that occurs in metal casting systems during filling. This model is an excellent predictor of porosity.
FLOW-3D Cast
FLOW-3D Cast has
a complete suite of tools for modeling solidification and pinpointing areas of excessive shrinkage or porosity, allowing you to
FLOW-3D Cast ’ s thermal
tracking capabilities help predict where oxides are likely to occur during the filling process. FLOW-3D Cast accurately tracks these oxides and their final locations.
predicts microporosity occurring late in the solidification stage, letting you make
design adjustments q uickly, avoiding critical and costly defects.
determine placement of risers to assure such defects are alleviated.
stress model enables you to predict precisely where stresses will occur and how a casting distorts. Stresses are simultaneously computed in the mold and in the solidifying metal.
DESIGN OPTIMIZATION
OXIDE FORMATION
AIR ENTRAINMENT
MICROPOROSITY
SOLIDIFICATION AND SHRINKAGE
THERMAL STRESS
FLOW-3D Cast ’s defect
The air entrainment model in FLOW-3D Cast is used to estimate the amount of entrained air that occurs in metal casting systems during filling. This model is an excellent predictor of porosity.
FLOW-3D Cast
FLOW-3D Cast has
a complete suite of tools for modeling solidification and pinpointing areas of excessive shrinkage or porosity, allowing you to
FLOW-3D Cast ’ s thermal
tracking capabilities help predict where oxides are likely to occur during the filling process. FLOW-3D Cast accurately tracks these oxides and their final locations.
predicts microporosity occurring late in the solidification stage, letting you make
design adjustments q uickly, avoiding critical and costly defects.
determine placement of risers to assure such defects are alleviated.
stress model enables you to predict precisely where stresses will occur and how a casting distorts. Stresses are simultaneously computed in the mold and in the solidifying metal.
DEFECT PREDICTION
I R O N S O L I D I F I C AT I O N
C O R E G A S G E N E R AT I O N
COOLING CHANNELS
DIE EROSION
The iron solidification model describes the eutectic and near-eutectic solidification of cast irons capturing the formation of austenite, graphite and carbide and the density variations that occur during the cooling process as these different phases form.
The core gas model predicts the effects of gas generation during the pouring and solidification process for resin-bonded cores. The core gas model predicts the location and quantity of gas defects and helps to design core venting that will safely evacuate the binder product gas from the cores.
Cooling channels are used in die casting and permanent mold casting for thermal management to prevent the overheating of the die and to c ontrol solidification. FLOW-3D Cast’ s cooling channel model includes time-dependent temperature and heat transfer coefficients and thermocouple-controlled activation
One of the causes of die erosion is cavitation, which occurs when metal pressure drops below a critical level due to flow separation and high velocities. This unsteady flow can be very damaging to dies. FLOW-3D Cast’ s cavitation potential model helps you determine where cavitation-induced die erosion might occur and make adjustments before casting.
for cooling and heating.
DEFECT PREDICTION
I R O N S O L I D I F I C AT I O N
C O R E G A S G E N E R AT I O N
COOLING CHANNELS
DIE EROSION
The iron solidification model describes the eutectic and near-eutectic solidification of cast irons capturing the formation of austenite, graphite and carbide and the density variations that occur during the cooling process as these different phases form.
The core gas model predicts the effects of gas generation during the pouring and solidification process for resin-bonded cores. The core gas model predicts the location and quantity of gas defects and helps to design core venting that will safely evacuate the binder product gas from the cores.
Cooling channels are used in die casting and permanent mold casting for thermal management to prevent the overheating of the die and to c ontrol solidification. FLOW-3D Cast’ s cooling channel model includes time-dependent temperature and heat transfer coefficients and thermocouple-controlled activation
One of the causes of die erosion is cavitation, which occurs when metal pressure drops below a critical level due to flow separation and high velocities. This unsteady flow can be very damaging to dies. FLOW-3D Cast’ s cavitation potential model helps you determine where cavitation-induced die erosion might occur and make adjustments before casting.
for cooling and heating.
FOUNDRY APPLICATIONS
DIE CASTING APPLICATIONS
DIE CASTING COLD CHAMBER OXIDE DEFECT ANALYSIS HELLEBUSCH TOOL & DIE
IDENTIFY POTENTIAL CASTING DESIGN The engineering team at H E L L E B U S C H T O O L & D I E ran a series of high pressure die casting filling simulations to identify possible defects in a steering wheel casting to see whether the casting design needed modification. The simulation results show that the majority of the oxides were trapped in the overflows. The top and bottom of the ba ck of the steering wheel indicate locations where overflows could be p laced to capture oxides to further improve the casting quality.
ISSUES BEFORE PART PRODUCTION
DIE CASTING COLD CHAMBER OXIDE DEFECT ANALYSIS HELLEBUSCH TOOL & DIE
IDENTIFY POTENTIAL CASTING DESIGN ISSUES BEFORE
The engineering team at H E L L E B U S C H T O O L & D I E ran a series of high
PART PRODUCTION
pressure die casting filling simulations to identify possible defects in a steering wheel casting to see whether the casting design needed modification. The simulation results show that the majority of the oxides were trapped in the overflows. The top and bottom of the ba ck of the steering wheel indicate locations where overflows could be p laced to capture oxides to further improve the casting quality.
COURTESY HELLEBUSCH TOOL & DIE
ACCURATELY MODEL ALL STAGES OF HIGH PRESSURE DIE CASTING: THERMAL DIE CYCLING,
HIGH PRESSURE DIE CASTING
SPRAY COOLING, SHOT SLEEVE OPTIMIZATION, FILLING AND SOLIDIFICATION.
FLOW-3D Cast provides highly-accurate solutions for die casters.
THERMAL DIE CYCLING Die cycling simulations are an essential component for high-pressure die casting. Simulations must provide accurate temperature distributions in a die throughout multiple die cycles. With FLOW-3D Cast, the temperature distributions for thermal die cycles are calculated for solidification,
die opening, spray, air blow, and die closing.
LADLE POURING & SHOT SLEEVE FLOW-3D Cast’s moving objects model
accurately captures the fluid motions throughout the process, giving you insights from the actual ladle pour to the fast shot. Test designs quickly by changing only a few parameters and compare optimized results
ACCURATELY MODEL ALL STAGES OF HIGH PRESSURE DIE CASTING: THERMAL DIE CYCLING, SPRAY COOLING, SHOT SLEEVE
HIGH PRESSURE DIE CASTING
OPTIMIZATION, FILLING AND SOLIDIFICATION.
FLOW-3D Cast provides highly-accurate solutions for die casters.
THERMAL DIE CYCLING Die cycling simulations are an essential component for high-pressure die casting. Simulations must provide accurate temperature distributions in a die throughout multiple die cycles. With FLOW-3D Cast, the temperature distributions for thermal die cycles are calculated for solidification,
die opening, spray, air blow, and die closing.
LADLE POURING & SHOT SLEEVE FLOW-3D Cast’s moving objects model
accurately captures the fluid motions throughout the process, giving you insights from the actual ladle pour to the fast shot. Test designs quickly by changing only a few parameters and compare optimized results easily with FlowSight.
Courtesy of Buhler
GRAVITY CASTING SOLUTIONS T E K S I D S.P.A. Filling of a gravity casting us ing the Moving Objects model to simulate a moving ladle with a prescribed motion that matches the actual machine setup. Filters are used in the runners in order to control the flow. The small viewport on the top left il lustrates a vertical section of the m old.
GRAVITY CASTING SOLUTIONS T E K S I D S.P.A. Filling of a gravity casting us ing the Moving Objects model to simulate a moving ladle with a prescribed motion that matches the actual machine setup. Filters are used in the runners in order to control the flow. The small viewport on the top left il lustrates a vertical section of the m old.
Courtesy of Teksid S.P.A. Post processed with EnSight®.
FOUNDRY CENTRIFUGAL CASTING FLOW-3D Cast provides highly-accurate filling
The higher pressure associated with centripetal
and solidification solutions for foundry processes.
acceleration in centrifugal castings, forces defects towards the rotational axis. FLOW-3D Cast’s
GRAVITY POUR CASTING
non-inertial reference frame model can prescribe
Part quality can be affected by entrainment of air
this rotation with the ability to modify its speed.
from overly-turbulent filling and by shrinkage-
This allows you to easily visualize and locate
induced defects. FLOW-3D Cast accurately tracks
potentially-costly defects.
the movement of the metal front, the location of potential defects and the evolution of temperatures during the filling process.
After filling is complete, the solidification of the metal, and its resulting shrinkage, can also be modeled.
INVESTMENT CASTING LOST FOAM CASTING FLOW-3D Cast’s special models simulate the entire
lost foam process, predicting where folds or other defects associated with trapped foam products are located. FLOW-3D Cast provides engineers
with the insight necessary to determine filling process parameters, such as pour temperature and pressure, gate sizes and locations.
FLOW-3D Cast’s
powerful numerical models can
simulate the complex investment casting process, allowing users to analyze wax injection, metal filling, and metal solidification as well as accurately predict defects. This analysis helps casting
companies improve component design, reduce defects, and shorten development time.
FOUNDRY CENTRIFUGAL CASTING FLOW-3D Cast provides highly-accurate filling
The higher pressure associated with centripetal
and solidification solutions for foundry processes.
acceleration in centrifugal castings, forces defects towards the rotational axis. FLOW-3D Cast’s
GRAVITY POUR CASTING
non-inertial reference frame model can prescribe
Part quality can be affected by entrainment of air
this rotation with the ability to modify its speed.
from overly-turbulent filling and by shrinkage-
This allows you to easily visualize and locate
induced defects. FLOW-3D Cast accurately tracks
potentially-costly defects.
the movement of the metal front, the location of potential defects and the evolution of temperatures during the filling process.
After filling is complete, the solidification of the metal, and its resulting shrinkage, can also be modeled.
INVESTMENT CASTING LOST FOAM CASTING FLOW-3D Cast’s special models simulate the entire
lost foam process, predicting where folds or other defects associated with trapped foam products are located. FLOW-3D Cast provides engineers
with the insight necessary to determine filling
FLOW-3D Cast’s
powerful numerical models can
simulate the complex investment casting process, allowing users to analyze wax injection, metal filling, and metal solidification as well as accurately predict defects. This analysis helps casting
companies improve component design, reduce defects, and shorten development time.
process parameters, such as pour temperature and pressure, gate sizes and locations.
NEW All-Electric Car BMW i3 B M W G R O UP Previously, structural parts in cars were made of steel meta l. Several advanced auto manufacturers have succeeded in manufacturing these parts as complex thin-walled light metal castings that are considerably lighter than the steel designs. This reduction in weight is espe cially important for electric cars that have to carry heavy batteries. Casting such complex and large parts is a very demanding task and requires fine tuning of ma ny parameters such as location and dimension of ingates, vents, overflows, shot curve, casting and die
temperatures . The use of simulation early on in development enables BMW engineers to optimize the HPDC process so that they can produce premium quality parts according to the specification of their new car designs.
Courtesy of BMW Group
NEW All-Electric Car BMW i3 B M W G R O UP Previously, structural parts in cars were made of steel meta l. Several advanced auto manufacturers have succeeded in manufacturing these parts as complex thin-walled light metal castings that are considerably lighter than the steel designs. This reduction in weight is espe cially important for electric cars that have to carry heavy batteries. Casting such complex and large parts is a very demanding task and requires fine tuning of ma ny parameters such as location and dimension of ingates, vents, overflows, shot curve, casting and die
temperatures . The use of simulation early on in development enables BMW engineers to optimize the HPDC process so that they can produce premium quality parts according to the specification of their new car designs.
Courtesy of BMW Group
BASIC
EXTENDED
ADVANCED
Al l BA SI C fe at ur es , pl us :
Al l EX TE ND ED fe at ur es , pl us :
•
Multi-block meshing, up to 5 mesh blocks
•
Filling, including viscous turbulence and surface tension effects
•
Unlimited mesh blocks for accurate
•
Solidific ation and heat transfer
•
Expandable database for cast alloys, molds, etc.
•
Chills, isolating sleeves and exothermic reactions
•
Temperature-dependent properties
•
Filters for flow control
mold temperature distribution
•
•
Track oxide formation and defects
and cooling line optimization for
•
Model moisture drying in molds and cores
•
Identify filling & solidificati on related porosity
temperature control
•
Vents
•
Natural convection of molten metal before solidificati on
Optimize shot sleeve performance
•
•
Cast iron solidificati on
•
Flow tracers
•
Lost foam castings and foam defects
•
Particle modeling
•
Locate cavitation to determine where
•
Filling and solidificati on analysis for
•
Binary segregation
•
Complete sand core suite
•
Trapped gases and venting effects
•
•
Thermal die cycling to determine
•
Permeable mold model for modeling air escape during filling
•
Six-degree s-of-freedom motion for prescribed shot sleeve and complex ladle pouring motion
Capture core gas release and associated defects
and apply motion to simulations
•
H I G H L Y -A C C U R A T E F L O W A N D S O L I D I F I C A T I O N R E S U L T S
Thermal- and mechanically-induc ed stresses and distortions
high pressure die castings
die erosion may occur
ALL FLOW-3D CAST PACKAGES FEATURE
•
and efficient simulations
Sand core blowing
Enhanced viscous effects including non-Newtonian viscosity, shear thinning/ thickening and thixotropic flows
•
Heating due to viscous shear
BASIC
EXTENDED
ADVANCED
Al l BA SI C fe at ur es , pl us :
Al l EX TE ND ED fe at ur es , pl us :
•
Multi-block meshing, up to 5 mesh blocks
•
Filling, including viscous turbulence and surface tension effects
•
Unlimited mesh blocks for accurate
•
•
Solidific ation and heat transfer
•
Expandable database for cast alloys, molds, etc.
•
Chills, isolating sleeves and exothermic reactions
•
Temperature-dependent properties
•
Filters for flow control
mold temperature distribution
•
•
Track oxide formation and defects
and cooling line optimization for
•
Model moisture drying in molds and cores
•
Identify filling & solidificati on related porosity
temperature control
•
Vents
•
Natural convection of molten metal before solidificati on
Optimize shot sleeve performance
•
•
Cast iron solidificati on
•
Flow tracers
•
Lost foam castings and foam defects
•
Particle modeling
•
Locate cavitation to determine where
and efficient simulations •
Thermal- and mechanically-induc ed stresses and distortions
Filling and solidificati on analysis for
•
Binary segregation
high pressure die castings
•
Complete sand core suite
•
Trapped gases and venting effects
•
•
Thermal die cycling to determine
•
Capture core gas release and associated defects
and apply motion to simulations
Sand core blowing
Enhanced viscous effects including non-Newtonian viscosity, shear thinning/ thickening and thixotropic flows
•
Heating due to viscous shear
die erosion may occur •
Permeable mold model for modeling air escape during filling
•
Six-degree s-of-freedom motion for prescribed shot sleeve and complex ladle pouring motion
ALL FLOW-3D CAST PACKAGES FEATURE H I G H L Y -A C C U R A T E F L O W A N D S O L I D I F I C A T I O N R E S U L T S AUTOMATIC MESHING FOR EASY MODEL SETUP MATERIAL LIBRARIES FOR METALS, MOLDS, FILTERS AND RISERS
FLOW-3D CAST
ACTIVE SIMULATION CONTROL
WITH ESCALATING LEVELS OF MODELING POWER:
FLOWSIGHT POSTPROCESSOR
B A S I C , E X T E N D E D a n d ADVANCED.
PACKAGES ARE AVAILABLE
LEARN MORE FLOW3D.COM/CAST
SUPPORT
COMPANY
Flow Science’s team of highly-experienced CFD support engineers prides itself on offering same day,
In 1963, while at the Los Alamos National Laboratory,
expert support by phone, email and live chat for the metal casting industry. Our dedicated support
Dr. C. W. “Tony” Hirt pioneered several landmark fluid
team is committed to the timeliness of your projects and successful implementation of FLOW-3D Cast.
dynamics methods, stability enhancing procedures and a unique free surface tracking technique—the
USERS SITE
“Volume of Fluid” or VOF method. In 1980, Dr. Hirt left
LANL to form Flow Science, Inc., with the mission to
Explore a variety of resources on the Users Site, such as:
develop a new generation of fluid dynamics modeling
•
Metal casting CFD checklists
capabilities for industrial and scientific applications.
•
Live chat
•
Example simulations
Flow Science now supports a worldwide customer base
•
Software updates
of commercial, academic and government users.
•
FAQs, validations and hints & tips
Our staff of sci entists and engineers constantly
•
Presentations, workshops and tutorials
strives to make innovative and useful improvements to our product suite.
In order to access the Flow Science Users site, you need an active lic ense and maintenance contract.
TRAINING Flow Science offers comprehensive training classes for FLOW-3D Cast in Santa Fe, NM. The 2-1/2 day training classes gi ve attendees a solid, working understanding of the software as well as hands-on experience with real-world simulations. We encourage potential users in addition to new and existing users to attend. One-on-one consultation is available; please call for details.
683 Harkle Road Santa Fe, New Mexico 87505 (505) 982-0088
[email protected]
LEARN MORE FLOW3D.COM/CAST
SUPPORT
COMPANY
Flow Science’s team of highly-experienced CFD support engineers prides itself on offering same day,
In 1963, while at the Los Alamos National Laboratory,
expert support by phone, email and live chat for the metal casting industry. Our dedicated support
Dr. C. W. “Tony” Hirt pioneered several landmark fluid
team is committed to the timeliness of your projects and successful implementation of FLOW-3D Cast.
dynamics methods, stability enhancing procedures and a unique free surface tracking technique—the
USERS SITE
“Volume of Fluid” or VOF method. In 1980, Dr. Hirt left
LANL to form Flow Science, Inc., with the mission to
Explore a variety of resources on the Users Site, such as:
develop a new generation of fluid dynamics modeling
•
Metal casting CFD checklists
capabilities for industrial and scientific applications.
•
Live chat
•
Example simulations
Flow Science now supports a worldwide customer base
•
Software updates
of commercial, academic and government users.
•
FAQs, validations and hints & tips
Our staff of sci entists and engineers constantly
•
Presentations, workshops and tutorials
strives to make innovative and useful improvements to our product suite.
In order to access the Flow Science Users site, you need an active lic ense and maintenance contract.
TRAINING Flow Science offers comprehensive training classes for FLOW-3D Cast in Santa Fe, NM. The 2-1/2 day training classes gi ve attendees a solid, working understanding of the software as well as hands-on experience with real-world simulations. We encourage potential users in addition to new and existing users to attend. One-on-one consultation is available; please call for details.
683 Harkle Road Santa Fe, New Mexico 87505 (505) 982-0088
[email protected]
LEARN MORE FLOW3D.COM/CAST
FLOW-3D
CAST
683 HARKLE RD S A N TA F E , N M 8 7 5 0 5 (505) 982-0088
