ProCAST finite element casting process simulation software

ProCAST- Casting simulation solutions

ProCAST Is a finite element method （FEM） Casting simulation software . The heat conduction including the thermal radiation considering the angle factor （ Heat convection ）, It includes the fluid flow of mold filling and the calculation of fully coupled temperature field （ thermodynamics ） The stress is simulated . Besides , Software can also be used for microstructure 、 heat treatment 、 Simulation of grain structure and shrinkage porosity .

Function is introduced

Shrinkage cavity

adopt ProCAST The standard solver can calculate the position of macro shrinkage cavity .ProCAST There is also a more refined model to simulate the location of pores , The model simulates the location of gas outlet by accurately calculating dendrite shrinkage and gas content

Stress distribution and deformation

ProCAST Has a unique heat 、 Flow and stress coupling analysis capability , also , This complete coupling analysis can be carried out on the same grid at the same time .ProCAST Be able to check the thermal shock generated during mold filling , And the influence of the gap between the casting and the mold during solidification . Solve hot cracking 、 Plastic deformation 、 Residual stress and distortion are the main concerns of current industrial users .

Microstructure and properties

Based on the difference of alloy composition , The software automatically calculates the corresponding microstructure and performance prediction . Such as ： The graphitization expansion of ductile iron castings can be accurately considered , So as to obtain meaningful simulation results . Coupling Microstructure module to accurately calculate the density defects of cast iron . At the same time, the strength of castings can be predicted based on the phase composition 、 hardness 、 Ductility and other properties .

CAFE Grain morphology

The grain structure of castings is the most desired casting parameter for metallurgists . A typical case is a gas turbine blade manufactured by directional solidification . In this investment casting process , Where the casting comes into contact with the cold iron , The alloy begins to solidify with very fine grains . In this equiaxed grain region , The crystalline direction of the grain grows preferentially according to the direction of heat flow , The growth of grains in other directions is inhibited . The extreme case is , In special applications where single crystals are required , Under strictly controlled solidification conditions , Make a crystal nucleus grow into a whole single crystal part .

ProCAST The change of grain structure during solidification can be calculated , It is used by many high-end industrial users to control casting conditions , Optimize component performance .ProCAST The finite element heat flow calculation and CA（Cellular Automation） Model coupling , therefore ProCAST The grain structure module of is often called by experts in the industry CAFE modular .

Advanced shrinkage and porosity

Most simulation software is limited to predicting shrinkage by identifying isolated liquid regions , This simplified method does not consider the effect of pores .

ProCAST It is the first commercial software to realize shrinkage and pore simulation based on physical methods , It couples the prediction of macroscopic shrinkage and tube shrinkage . Flow calculation in the mushy region and based on Darcy equation （Darcy,s equation） Relevant pressure drop . in addition ,ProCAST There is a gas segregation model considering both solubility and micropore nucleation and growth . This comprehensive approach extends the ability of casting professionals to explore and understand casting process conditions 、 Complex relationship between alloy purity and prediction of shrinkage porosity .

Parallel solution

ProCAST Both finite element module solver and differential module solver in casting analysis software support parallel computing .ProCAST Of DMP Solution （ Memory distributed parallel computing ） The latest dynamic volume partition and information communication technology are used .DMP The version includes the main filling and solidification module functions of the software , Including radiation 、 Stress calculation 、 Microstructure calculation , And used in Linux and Windows platform . In order to simulate the actual industrial conditions in metal casting ,ProCAST The thermal cycle simulation is provided to achieve the stable temperature state of the die , If parallel computing is adopted, the solution can be completed in a few minutes .

Optimize the calculation

Optimization is to automatically find the optimal conditions （ Such as process design scheme and parameters ） To achieve design objectives （ Minimize shrinkage porosity 、 Improve the process yield and so on ）, It is not necessary to judge after each simulation .

Design optimization

adopt Visual-OPT Can automatically find the best design scheme ：

Riser size and position 、 Cold iron position 、 Gate location 、 Runner size

Optimization of process parameters

adopt Visual-OPT It can automatically find out the optimal process parameters ：

Pouring temperature 、 Pouring speed 、 Mold temperature

For customer requirements , Such as minimizing shrinkage , Minimize oxidation slag inclusion 、 Improve die life 、 Avoid entrapment in the pressure chamber ... Compared with the traditional “ Trial and error method ”,Visual-OPT It's the lowest cost , The most economical tool .

Process stability and experimental design

As a casting engineer, you must also evaluate the process stability and the influence of various process parameters , Such as pouring temperature 、 Mold temperature, etc . By optimizing the algorithm , After a few calculations （ Based on random method ） The relationship between shrinkage defects and these process parameters can be obtained . for example , Use Visual-OPT This function of , According to the shrinkage sensitivity of the part , It is easy to determine the safest process parameter value .

The process template

stay VE The environment shall be provided according to the process division Workflow function , It can guide users to 、 Complete parameter setting accurately . The process setting can effectively improve the setting efficiency , At the same time, the error rate of setting is reduced . at present VE The process templates provided in the environment for the casting process are ： Gravity process flow template 、 High pressure casting process flow template 、 High pressure die casting machine selects process template and optimizes process template , Other process templates will be added in the development of subsequent processes .

Multi process flow

The multi-stage process template is strengthened for the general process , This process template can set up multiple stages in the casting simulation process at one time , Such as the removal of mold 、 Heating and cooling of castings after removal of gating system and mold . Set when submitting calculation , The software can automatically generate the required calculation files .

ProCAST Process application

Investment casting

ProCAST Based on the finite element mesh, the mesh of mold shell and insulation layer can be automatically generated , The insulation grid can be set as anisotropic , Thus, the thickness parameters can be adjusted at any time without regenerating the mesh . For superalloys   Solidification process under vacuum , Have a professional radiation heat exchanger .

  Low pressure metal type / Sand casting

Real reproduction of industrial production conditions , Realize multiple simulation of mold temperature until stable state . Under this condition, the casting is filled / Simulation calculation of solidification process , Optimize process parameters , Reduce trial production , Shorten the production cycle .

  Gravity casting （ Sand mold , Metal type , Tilt ）

For gravity casting , The key factor is how to optimize the gating system and how to eliminate possible shrinkage areas .proCAST Can be poured , freezing , Simulation of stress and microstructure , The design scheme of the technologist is reproduced on the computer , Help determine its enforceability .

High pressure casting

The high pressure casting process is closely related to the mold and die casting machine equipment ,ProCAST The software can simulate the whole production process of high pressure casting , Including liquid metal injection in the pressure chamber , Multistage injection process, etc . At the same time, it has the database of die casting machine , According to the actual casting process and casting parameters , analysis PQ² chart , Determine the process window , Combined with simulation effect , Optimize the relevant parameters .

Centrifugal casting

ProCAST The software has a professional vertical centrifugal casting simulation module , Under different centrifugal speed parameters , Filling and solidification process of castings .

Continuous casting

ProCAST It provides a complete solution for continuous casting and semi continuous casting process simulation . The continuous casting process can be simulated in two ways ：1、 Steady state simulation , Fixed model , Solid metal passes through the mold area at casting speed ;2、 Unsteady state simulation , Transient simulation , The model extends with the casting process , This area is extended by MiLE Algorithm -Mixed lagrangian –Eulerian.

Lost foam casting

The influence of foam combustion area and pressure on mold filling process should be considered in EPC simulation , And the permeation of gas and sand after combustion .ProCAST The software has a professional physical model , Precisely handle the complex process behind the disappearance .

Semi solid casting

Casting process simulation ProCAST From getting started to mastering document downloading When a semi-solid material is injected into the mold cavity , Its speed depends on the shear rate of itself and the material previously injected into the cavity . If the shear rate is large , Then the solidified dendrites are destroyed , Liquidity will increase ,ProCAST Professional models have been developed to solve such problems .

Sand shooting and core making

The sand shooting core making module is ESI GROUP And Asland,CTI,CTIF,IMFT,Infun,Laempa,Teksid and Weir Foundry joint development .

ProCAST The core making process module can accurately predict the sand shooting process and gas defects , Including incomplete filling , Compressive strength and low hardness areas .

QuikCAST Focus on foundries ： Filling 、 Prediction of solidification and shrinkage porosity .ProCAST Based on finite element technology , Deformation and residual stress can be predicted , It can also be used in more special processes , Such as semi-solid 、 Sand shooting and core making 、 Centrifugal casting 、 Lost foam casting and continuous casting .