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Quick Simulation
 
Simulate existing castings to find out the causes for internal defects or poor yield. Simulate new castings to reduce the number of foundry trials.

 

  • Simulate layer-by-layer mold filling to check mold erosion (sand inclusions)
  • Estimate the filling time to check if the filling is too slow or too fast
  • Simulate casting solidification in three different ways:
    • Cooling animation (3D and 2D sections) to check hot spots
    • Feed metal path simulation to check feeding distance
    • Interpret the results to check for macro and micro shrinkage
Melt-jet simulation Filling simulation Solidiifcation simulation Shrinkage

Based on the results of simulation, you can change the methods design and simulate again. Each iteration of methods design modification and simulation takes less than half hour. The program can also automatically optimize feeder size for the desired quality, and gating sizes for the desired filling time.

 

Why feeder necks are sensitive

 

An undersized neck leads to shrinkage porosity on both sides (feeder as well as casting), whereas an oversized neck leads to porosity in the neck region extending into the casting. Neck design based on geometric modulus cannot guarantee defect-free casting, since the area around the neck is usually hot and its effective modulus is more than the calculated value. Using AutoCAST-X, you can model and simulate different neck designs within minutes, to decide the best configuration.

 

Neck Design  
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