FLOW-3D CAST v5.1

FLOW-3D CAST v5.1 provides casters with a complete simulation tool for modeling all the casting processes commonly found in modern foundries. Highlights of the FLOW-3D CAST v5.1 release include new process workspaces for investment casting, sand core making, centrifugal casting, and continuous casting, an expansive database of exothermic risers, and a brand new, chemistry-based alloy solidification model.

A major development in FLOW-3D CAST v5.1 is our new, award-winning alloy solidification model. This ground-breaking achievement provides casters with the ability to predict casting strength characteristics and reduce material usage while still meeting product safety and performance requirements.

The new process workspaces greatly reduce simulation setup and results analysis time. The Investment Casting Workspace features a fast and accurate shell mold generation tool and a full radiation model. The Sand Core Making Workspace models sand core shooting as well as all the hardening processes. The Centrifugal Casting Workspace provides the most accurate simulation tool available for all centrifugal processes. Finally, the Continuous Casting Workspace simulates all continuous casting processes including direct chill.

Additionally, databases for heat transfer coefficients, air vents, HPDC machines, and risers provide information at the users’ fingertips. The new exothermic riser database along with the solidification hotspot identification tool lets users quickly and easily place an appropriately sized exothermic riser at locations where shrinkage is predicted to occur.

State-of-the-art Solidification Model

FLOW-3D CAST v5.1 features a new, state-of-the art, chemistry-based solidification model that advances solidification modeling into the next frontier of casting simulation – the ability to predict the strength properties of castings. Using only readily-available chemical compositions of alloys, users will be able to determine properties such as ultimate tensile strength, elongation, and thermal properties such as thermal conductivity. Additionally, the new solidification model provides output such as the dimensionless Niyama criteria and micro-porosity for more accurate assessments of porosity issues.

Many factors affect the mechanical properties of a casting. These properties are primarily determined by the microstructure which is in turn determined by factors such as the solidification rate, segregation rate, and nucleation. Using the new solidification model, process designers can determine the effect of various process parameters and alloy compositions on the mechanical properties to optimize the performance of their castings to produce the highest quality, safest products possible.

Investment Casting Workspace

The Investment Casting Workspace is a streamlined tool for simulating investment casting processes such as filling, solidification (with either static or moving shell molds), and cooling. A shell mold creation tool allows users to quickly and reliably create a shell mold of any thickness. A wide range of controls are available for generating radiating clusters, computing view factors of participating radiating surfaces and reducing computational overhead. In castings such as turbine blades, where grain growth is controlled by directional solidification, a moving oven with a hot upper section separated by a baffle from a cooler lower section can be modeled.

FLOW-3D CAST is a state-of-the-art metal casting simulation modeling platform that combines extraordinarily accurate modeling with versatility, ease of use, and high performance cloud computing capabilities. For every metal casting process, FLOW-3D CAST has a workspace ready to put you on a quick, intuitive path to modeling success. With 11 process workspaces, powerful post-processing, pioneering filling and solidification and defect analysis, FLOW-3D CAST delivers both the tools and roadmap for designing optimal casting solutions.

HPDC

Tilt Pour Casting

Centrifugal Casting

Investment Casting

Low Pressure Sand Casting

Continuous Casting

Low Pressure Die Casting

Lost Foam Casting

Sand Core Making

Gravity Die Casting

Sand Casting

Solidification shrinkage model improvements

This new release incorporates an improved solidification shrinkage model with revised porosity outputs in the new EXODUS format, allowing users to simplify the analysis and interpretation of porosity. Porosity outputs now include resolved shrinkage porosity, helping engineers better visualize leak paths.

Improved treatment of solidified metal in the shot sleeve

In high pressure die casting (HPDC), defects such as cold shuts and misruns in the finished casting can originate from early solidification in the shot sleeve. Users can now capture the movement of solidified metal in the shot sleeve with the porosity-based solidification model, providing a much more accurate thermal profile during fill.

Improved valve model

Valves and air vent components in FLOW-3D CAST are used to model venting systems in casting assemblies, which can be crucial for removing defects from the casting part. Users can now more accurately predict the final location of defects with the improved valve model by specifying a target volume of metal allowed to exit valves and vents.