Finite Element and CFD Based Simulation of Casting
Using Sophisticated FEA and CFD technologies, Enteknograte Engineers can predict deformations and residual stresses and can also address more specific processes like investment casting, semi-solid modeling, core blowing, centrifugal casting, Gravity Casting (Sand / Permanent Mold / Tilt Pouring), Low Pressure Die Casting (LPDC), High Pressure Die Casting (HPDC), Centrifugal Casting and the continuous casting process. The metal casting simulation using FEA and CFD based technologies, enable us to address residual stresses, part distortion, microstructure, mechanical properties and defect detection include:
- Solidification: Micro Porosity, Gas Porosity
- Stress: Hot Tears, Surface Cracks, Residual Stresses, Cold Cracks, Distortion, Die Fatigue
- Metallurgy Specifications: Stray Grain, Freckle, Segregation, Distortion
- Pouring: Misruns, Air Entrapment, Oxides, Surface Defects, Cold Shuts, Turbulences, Inclusions, Core Gases
With deep knowledge in Finite Element and CFD based Simulation Technologies, Enteknograte Engineers can predict evaluations of the entire casting process, including filling and solidification defects, mechanical properties and complex part distortion. It enables you to understand the effects of design changes and provides a basis for correct decision-making, from the earliest stages of the manufacturing process and optimize your time and cost.
Low pressure die casting
Low pressure die casting, LPDC, is a process in which a ceramic tube is connected to a steel die above and extends into a furnace of molten metal below. The furnace is then pressurized to fill the part by forcing fluid up through the sprue. Once the casting has solidified the air pressure is reduced allowing the rest of the metal still in liquid form in the tube to recede back into the furnace. Low pressure die casting is used for high production rates, thicker parts up to 2.5 mm, for better surface quality, and when high temperature heat treatment is needed to improve strength.
Based on problem description, FEA or CFD tools used with Enteknograte engineering team to better design many aspects of a low pressure die casting through modeling thermal die cycling, filling, and solidification including thermally induced stresses and displacements. Better designs before production help alleviate trial and error through experimentation and bring designs to production more quickly. Both of which help save time and reduce costs.
Reduce Development Cost
Test Before Manufacturing
Casting Simulation Features:
Thermal aspect of Casting Simulation
The heat release associated with phase changes such as solidification and solid phase transformations is described by an enthalpy formulation. Casting issues addressed by the thermal solver include:
- Hot spots and Thermal Modulus
- Macro and micro shrinkage
- Die cooling and heating optimization
- Runner and riser design
- Pin Squeeze
Automated Structural Optimization
Design optimization is a critical element in product development, but is often very iterative and requires a great deal of manual effort. We use advanced optimization algorithms that automatically seek optimal configurations in an allowed design space.
- Optimize for stress, mass, fatigue, etc. while varying design variables such as material properties, geometric dimensions, loads, etc.
- Enhance the shape or profile of structural members with shape optimization
- Find optimal thicknesses with topometry optimization
- Determine optimal bead or stamp patterns for metal parts with topography optimization
- Remove excess and unnecessary volume with topology optimization
- Simultaneously optimize multiple models across disciplines with Multi Model Optimization