FLOW-3D CAST Advanced 3.5.2

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The High Pressure Die Casting Workspace is an intuitive modeling environment designed to help engineers successfully model high pressure die casting applications with

FLOW-3D CAST. Full control of shot sleeve motion, combined with advanced die thermal control, machine parameter modeling, and accurate resolution of fill and backpressure conditions make FLOW-3D CAST the reference solution for the most demanding HPDC simulation needs. In addition to advanced porosity prediction and post-processing functionalities, the HPDC Workspace includes a state-of-the-art chemistry-based solidification and material strength model for Al-Si and Al-Cu based alloys.

This is a simulation of an automotive flywheel or bell housing, showing velocity contours of an aluminum alloy during a fast shot of a high pressure die casting process. It is part of a design phase to evaluate different gating options. Shown here is a comparison of five gates, simulating filling from a runner below the parting line to accomplish an 80-millisecond casting fill. The left-hand simulation in the video shows gates pointed upward below the parting line, while the right-hand simulation shows gates at the same location, angled at 45 degrees. Learn more at www.flow3d.com/cast.

FLOW-3D CAST Advanced 3.5.2

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This investment casting simulation is used to compare the mold temperature distribution between radiating and non-radiating models.

FLOW-3D CAST v5.1 contains a full body to body radiation model to accurately capture the solidification and cooling dynamics after fill.

The Investment Casting Process Workspace in

FLOW-3D CAST v5.1 offers automatic shell generation in addition to advanced radiation modeling, in order to deliver extraordinary accuracy to aid the design modeling process.

FLOW-3D POST is a flexible, powerful post-processing tool which allows the user to easily change focus from cell-level point property investigations up to complete scene advanced rendering. In this training we will explore two common post-processing functions. We will first learn how to extract point value information for either troubleshooting or run-time improvement purposes. This part is deeply technical but offers the reward of providing insights into why a simulation may be running into numerical difficulties or inefficiencies. In the second part we learn how to create compelling images and animations by exploiting advanced rendering effects using vectors, ray tracing and moving camera effects.

Engineers need to be able to deliver project analyses faster and more efficiently than ever before. This is why

FLOW-3D and FLOW-3D CAST have built-in options for workflow automation, a modular text-driven structure that allows for easy scripting, and batch postprocessing. In this advanced training, we will review the features that can help you save time and money through automation and optimization.

Flow Science announced that it has released a new version of FLOW-3D CAST, its software for the metal casting industry. FLOW-3D CAST 4.2 offers an advanced What You See Is What You Need (WYSIWYN) interface, process-oriented workspaces and a new die spray cooling model.

Flow Science Releases FLOW-3D CAST 4.2:

About FLOW-3D CAST. FLOW-3D CAST provides a complete flow and thermal solution for a wide range of metal casting processes. The simulations provide detailed insights into filling and solidification of the cast part while tracking various defects like different types of porosity, surface oxides, entrained air and collapsed bubbles, thermal stresses and deformations and more. Metal casters can also analyze the mold or die thermal profiles and other properties like gassing of cores with FLOW-3D CAST. Optimized simulated designs reduce development time on the plant floor, speed up time to market and increase yield. FLOW-3D CAST enables modelers to save on design and development costs when deploying new casting processes or alloys.

Combining an intuitive and progressive user interface, FLOW-3D CAST guides modelers through successful projects delivering accurate predictions of filling and solidification defects. Available in Suites for sand casting, permanent mold casting, and high pressure die casting, modelers can use the Suite that best matches their process requirements.

87-23 Prosenjit Das, Optimisation of melt pouring temperature and low superheat casting of Al-15Mg2Si-4.5Si composite, International Journal of Cast Metals Research, 36.1-3; 2023. doi.org/10.1080/13640461.2023.2211895

60-23 Yuanhao Gu, Feng Wang, Jian Jiao, Zhi Wang, Le Zhou, Pingli Mao, Zheng Liu, Study on semisolid rheo-diecasting process, microstructure and mechanical properties of Mg-6Al-1Ca-0.5Sb alloy with high solid fraction, International Journal of Metalcasting, 2023. doi.org/10.1007/s40962-023-01001-0

45-23 Daniel Martinez, Philip King, Santosh Reddy Sama, Jay Sim, Hakan Toykoc, Guha Manogharan, Effect of freezing range on reducing casting defects through 3D sand-printed mold designs, The International Journal of Advanced Manufacturing Technology, 2023. doi.org/10.1007/s00170-023-11112-x

38-23 Emanuele Pagone, Christopher Jones, John Forde, William Shaw, Mark Jolly, Konstantinos Salonitis, Defect minimization in vacuum-assisted plaster mould investment casting through simulation of high-value aluminium alloy components, TMS 2023: Light Metals, pp. 1078-1086, 2023.

33-23 Philip King, Guha Manogharan, Novel experimental method for metal flow analysis using open molds for sand casting, International Journal of Metalcasting, 2023. doi.org/10.1007/s40962-023-00966-2

31-23 Anand Kumbhare, Prasenjit Biswas, Anil Bisen, Chandan Choudary, Investigation of effect of the rheological parameters on the flow behavior of ADC12 Al alloy in rheo-pressure die casting, International Journal of Metalcasting, 2023. doi.org/10.1007/s40962-023-00962-6

24-23 Natalia Raźny, Anna Dmitruk, Maria Serdechnova, Carsten Blawert, Joanna Ludwiczak, Krzysztof Naplocha, The performance of thermally conductive tree-like cast aluminum structures in PCM-based storage units, International Communications in Heat and Mass Transfer, 142; 106606, 2023. doi.org/10.1016/j.icheatmasstransfer.2022.106606

172-22 J. Yokesh Kumar, S. Gopi, K.S. Amirthagadeswaran, Redesigning and numerical simulation of gating system to reduce cold shut defect in submersible pump part castings, Proceedings of the Institution of Mechanical Engineers, Part E: Journal of Process Mechanical Engineering, 2022. doi.org/10.1177/0954408922114218

125-22 Maximilian Erber, Tobias Rosnitschek, Christoph Hartmann, Bettina Alber-Laukant, Stephan Tremmel, Wolfram Volk, Geometry-based assurance of directional solidification for complex topology-optimized castings using the medial axis transform, Computer-Aided Design, 152; 103394, 2022. doi.org/10.1016/j.cad.2022.103394

71-22 M. G. Mahmoud, Amr Abdelghany, Serag Salem, Numerical simulation of door lock plates castings produced by high pressure die casting process, International Journal of Metalcasting, 2022. doi.org/10.1007/s40962-022-00797-7

70-22 Andreas Schilling, Daniel Schmidt, Jakob Glück, Niklas Schwenke, Husam Sharabi, Martin Fehlbier, About the impact on gravity cast salt cores in high pressure die casting and rheocasting, Simulation Modelling Practice and Theory, 119; 102585, 2022. doi.org/10.1016/j.simpat.2022.102585

52-22 Manthan Dhisale, Jitesh Vasavada, Asim Tewari, An approach to optimize cooling channel parameters of low pressure die casting process for reducing shrinkage porosity in aluminium alloy wheels, Materials Today: Proceedings, in print, 2022. doi.org/10.1016/j.matpr.2022.03.478

44-22 Zihan Lang, Feng Wang, Wei Wang, Zhi Wang, Le Zhou, Pingli Mao, Zheng Liu, Numerical simulation and experimental study on semi-solid forming process of 319s aluminum alloy test bar, International Journal of Metalcasting, 2022. doi.org/10.1007/s40962-022-00788-8

117-21 I. Rajkumar, N. Rajini, T. Ram Prabhu, Sikiru O. Ismail, Suchart Siengchin, Faruq Mohammad, Hamad A. Al-Lohedan , Applicability of angular orientations of gating designs to quality of sand casting components using two-cavity mould set-up, Transactions of the Indian Institute of Metals, 2021. doi.org/10.1007/s12666-021-02434-z

106-21 M. Ahmed, E. Riedel, M. Kovalko, A. Volochko, R. Bähr, A. Nofal, Ultrafine ductile and austempered ductile irons by solidification in ultrasonic field, International Journal of Metalcasting, 2021. doi.org/10.1007/s40962-021-00683-8

82-21 Giulia Scampone, Raul Pirovano, Stefano Mascetti, Giulio Timelli, Experimental and numerical investigations of oxide-related defects in Al alloy gravity die castings, The International Journal of Advanced Manufacturing Technology, 117; pp. 1765-1780, 2021. doi.org/10.1007/s00170-021-07680-5

74-21 Shuyang Ren, Feng Wang, Jingying Sun, Zheng Liu, Pingli Mao, Gating system design based on numerical simulation and production experiment verification of aluminum alloy bracket fabricated by semi-solid rheo-die casting process, International Journal of Metalcasting, 2021. doi.org/10.1007/s40962-021-00648-x

44-21 Yunxiang Zhang, Haidong Zhao, Fei Liu, Microstructure characteristics and mechanical properties improvement of gravity cast Al-7Si-0.4Mg alloys with Zr additions, Materials Characterization, 176; 111117, 2021. doi.org/10.1016/j.matchar.2021.111117 75035a25d1

FLOW-3D CAST Advanced 3.5.2

FLOW-3D CAST Advanced 3.5.2

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