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FLOWCast EXAMPLE

Below you can see a Pouring simulation of a stainless steel investment casting using FLOWCast.

FlowCast

FLOWCast is sold as an additional module although SOLIDCast contains its own mould filling algorithm, which is adequate for many casting operations.

However, SOLIDCast lacks FLOWCast’s ability to simulate mould erosion and other metallic velocity and pressure related effects.

FLOWCast - Fluid Flow Modeling Module

If mould erosion or oxide film entrapment in metals (e.g. aluminium bronze) is a problem, then the ability to study exactly what happens in pouring is crucial, and FLOWCast’s advantages are hard to refute. The larger and more expensive the casting the more essential FLOWCast becomes.

Flow modelling demonstrates how molten metal flows through gating systems and fills the mould cavity. FLOWCast also models convection, conduction and radiation within the mould cavity. This allows you to predict and minimize flow-related defects, misruns, oxide formation and mould erosion due to excessive filling velocities.

FLOWCast offers a fully-featured CFD (Computational Fluid Dynamics) simulation of flow, based on solution of the Navier-Stokes equations. You can view progressive temperature, fluid velocity and fluid pressure during the fill, from any angle of view.

FLOWCast uses models and meshes created with the easy to use SOLIDCast. Just import your casting model from 3D CAD or build your model using SOLIDCast tools, mesh the model and run FLOWCast to simulate mould filling.

When the FLOWCast mould filling simulation is complete the results are saved in a way that allows subsequent analysis and creation of videoclips to examine thermal, velocity and pressure conditions applying throughout mould filling. The liquid metal-filled mould is then passed automatically to SOLIDCast for the freezing stage to be simulated.

FLOWCast Simulations

The two FLOWCast examples shown in videoclips below are very different. In the first an iron cylinder head casting is analyzed for the velocity experienced by inflowing liquid metal. Colour variations pale turquoise to dark blue show velocities varying from quite brisk flowing to virtually static.

In the second example a steel pipe fitting section is poured using an interesting methoding layout. The initially active ingates are bottom feeding, but as the metal level reaches the top of the pipe section fresh hot metal is supplied from two higher level ingates.

FLOWCast pouring simulation of a vehicle cylinder head casting
This simulation shows metal flow velocities.
See colour scale for velocities in m/sec.

FLOWCast simulation of mould filling of a pipe casting
The black particle traces illustrate turbulence in the metal flow.