27/12/2021
News
Over the years, the need to simulate the wax injection department has also emerged. ESI has developed a dedicated module, capable of virtualizing Non-Newtonian materials, waxes and has introduced the "PRO-S-38-Flow Solver-Non-Newtonian" module.
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27/12/2021
Success stories
Advanced casting simulation tools like Procast™ allow the foundry engineer to quickly bridge the gap between design and manufacturing. Optimisation or improved efficiency during the manufacturing cycle leads to substantial time and cost savings. Computer analysis provides the means for verifying design ideas and viewing the effects of “what ifs” at minimal costs by avoiding time-consuming and expensive rework and retooling.
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27/12/2021
Success stories
Numerical simulation tools for continuous casting processes have recently been enriched with a new innovative technique based on a Mixed Lagrangian Eulerian Method (further noted as MiLE) implemented in the finite element software ProCAST. In order to treat non-steady phenomena in continuous casting, one has to consider an extending computation domain ...
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27/12/2021
Newspapers & Magazines
ProCAST allows to calculate stress and deformation and therefore also the gap formation between casting and mould.
Figure 2 shows the important facts for the heat transport between interfaces and also the tasks which are solved by the ProCAST approach.
Since the meshes of the casting and the mould are both deformed in function of the temperature it is not only necessary to find the elements which are facing each other by the non coincident interface algorithm but also to ...
27/12/2021
Success stories
THE BENEFITS
. Improved part quality;
. Reduced development phase;
. Savings in energy, material and tooling modification costs;
. Tool design and process optimization with simulation, allowing development of best fit conditions for real-time manufacturing
27/12/2021
Success stories
The lost foam casting process has been successfully simulated using process modelling software, taking into account the burn-out of the pre-form foam pattern, the thermal heat transfer across the pyrolytic zone, the influences of the ceramic coating as well as the transport of gasses from the pyrolytic zone through the mould.
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27/12/2021
Success stories
This paper presents several case studies on the use of ProCAST in lost foam simulation The Lost Foam Casting process eliminates the need for sand binders and cores. The sand is unbounded and a foam pattern is used to form the shape of the casting. Foam patterns are created from polystyrene beads. The beads start as hard granules, very similar in size and shape to sand granules. The beads are expanded after they are injected into the desired shape.
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27/12/2021
Success stories
“This problem would have taken about 12 weeks and $6,000 in pattern changes plus countless hours of machine time to solve using conventional trial and
error methods. With QuikCAST, we can easily solve similar problems in 2 weeks and produce a good pattern the first time. We have used simulation on about 20 parts to date and the simulation results are similar to what we see in the shop."
Dan Rudolph
Quality Engineer
J. Walter Miller Company
26/12/2021
Success stories
CHAPTER 5
Simulation of the casting process
Introduction
In order to characterize the behavior and the Hot Tearing tendency of the light alloys chosen for our investigation, we used one of the most popular casting simulation software, ProCAST®, produced by the French ESI Group, used in the complete version of stress module, thanks to the kind collaboration offered by the Italian distributor ECOTRE.
Article in Italian
26/12/2021
Success stories
The goal of this e-tip is to illustrate the simulation methodology in case of gravity casting. In order to optimize a casting design in an efficient way, it is recommended to proceed the simulation step by step:
1) casting solidification only
2) positioning of the risers
3) filling study
4) experimental validation
22/12/2021
Success stories
Modelling of porosity in centrifugal casting. An important aspect of the new casting modeling capabilities integrated in ESI casting solution ProCAST capability of taking into account the centrifugal forces on the porosity formation.
The modelling capabilities developed in COLTS were integrated in the commercial software package ProCAST. By this the aeronautic and space industry is provided with a professional software solution to further produce such complex titanium parts with a well controlled casting process.
22/12/2021
Technical papers
In the simulation software QuikCAST Light and QuikCAST there is the simulation module for shooting and gassing cores.
By simulating the process, it is possible to gain a better understanding of these interactions and significantly reduce the lengthy development phase of trial and error, similar to what happened in the 1990s with the simulation of the casting process.
