Mold flow CAE (fluid simulation technology) casting applications

Nowadays, with the development of computer software, artificial intelligence, simulation and analysis software accuracy and credibility, mold flow analysis software in the casting industry is more and more common. cae simulation technology is widely used in the development of casting molds and product production. Today, I will introduce the widely used in the industry software magma, flow3d, procast, anycasting, China casting CAE, others have novcast, jscast. more professional simulation soft or: anysys , star ccm wait for the software, this kind of software is more complex, mainly for automobiles, airplanes, ships simulation.

rationale

CAE (Computer Aided Engineering) is based on the basic principles of fluid dynamics and solves the equations of motion of a fluid by numerical methods in order to simulate the flow state of the fluid. These equations typically include the equations of conservation of mass, conservation of momentum, and conservation of energy. By solving these equations, the distribution of parameters such as velocity, pressure, and temperature of the fluid under specific conditions can be obtained.

Casting simulation CAE mainstream software

Mold flow CAE technology is a fluid simulation technology based on computer technology, which uses mathematical models and algorithms to simulate and analyze fluid flow. In the field of casting, mold flow CAE technology can simulate the charging and solidification process of metallic fluids in the mold, including the flow rate, pressure distribution, temperature field changes, etc., to help engineers better understand and control the casting process.

Magmasoft

MAGMASOFT software is a cae simulation software opened by a German company specializing in the foundry industry. The software can be the rightcast (pour metal into a mold)Comprehensive simulation and analysis of mold filling, solidification, cooling, heat treatment, stress and strain. The simulation technology of the software makes the complex casting process digital, visualization, easier to be observed and understood by the foundry. At the same time, the calculation speed is faster, almost a working day. There is no problem with thin-walled parts (FLOW3D headache for thin-walled products), the software heat shrinkage results are accurate, but the software flow is not as good as flow3d and procast.

Flow3d

FLOW3D was developed in the United States and is widely used. It is a general-purpose software widely used in aerospace industry, metal casting, coatings, consumer products, micro inkjet heads, marine transportation, microelectromechanical systems, hydrodynamics, etc. FLOW3D has been used in die casting with very high accuracy, with reasonable parameter settings, and the flow accuracy can reach more than 90%. FLOW3D employs a very important fluid dynamics method, such as improved stability and unique free surface tracking (VOF) technology, which makes the results more realistic and more like the die-casting process. FLOW3D is easy to operate, with few interfaces and procedures, which is a good feature. The only disadvantage is that the calculation time will be longer, usually one day to three days. If the product is very large (500mm*400mm*300mm), the calculation will take nearly four days. And the requirement for mesh processing is also higher. Compared with the Korean software anycasting, everyone feels that the flow embodiment is more similar. But the accuracy of details is much higher than anycasting.

Procast

American Procast Software UES (UNIVERSALENERGY SYSTEM) company developed casting process simulation software. There are a lot of modules and it is fast, but the meshing is a bit anti-human, the parameters are more comprehensive, and it requires a lot of people to input. Compared to other CAE casting simulation and analysis software, driving a manual transmission is more automatic. In terms of flow and heat shrinkage, the software simulation results are relatively accurate, parameter settings in line with the reality can be achieved when the accuracy of 90% or more. Even higher.

Anycasting

Anycasting is a new generation of advanced casting simulation software system based on Windows operating platform, specially developed for various casting process simulation system. After years of iterative upgrades, the software has a powerful Real Flow solver and three-dimensional processing technology can simulate a variety of casting processes, including die casting,Low-pressure castingIt provides users with efficient, accurate and realistic casting simulation and analysis results, such as sand casting.

Huaji CAE

"Huacasting CAE is an integrated software system, located in Huazhong University of Science and Technology, after more than 30 years of research and development, and constantly improved and perfected in long-term production practice. With the numerical simulation technology of casting charging and solidification process as the core, it carries out process analysis and quality prediction of casting molding process, and assists technicians to complete the process optimization of casting. The software simulates the charging and solidification process of castings on the computer, and predicts the defects that may occur in the casting process, such as air roll, slag entrapment, sand flushing, insufficient pouring, cold segregation, shrinkage, shrinkage and loosening.

Foundry applications

Simulation and optimization of casting processes

1. Simulation of the filling process:
   • CAE fluid simulation technology can accurately simulate the flow filling process of metal fluid in the mold, including speed, direction, and shape of the leading edge.
   • Through simulation, it is possible to predict possible defects such as air rolls, cold segregation, underpouring, etc. that may occur during the filling process. Improvement of deficiencies
2. Simulating the solidification process:
   • CAE technology can simulate the solidification process of metallic liquids, including the variation of temperature field, distribution of solidification time, and solidification sequence.
   • Through simulation, solidification defects such as shrinkage holes and shrinkage loosening can be predicted and optimized, and the solidification sequence can be changed to improve the quality of castings.

Casting Process Design

1. Riser and Cold Iron Design:
   • CAE fluid simulation technology is used to assist in the design of the location, size and shape of risers and cold irons to ensure that castings are adequately contracted and cooled during solidification.
   • Through simulation, the design of risers and cold irons can be optimized to reduce casting defects and improve casting yield.
2. Pouring system design:
   • CAE technology can simulate the flow of the pouring system, including the distribution, flow and flow of the metal liquid.
   • Through simulation, the design of the pouring system can be optimized to ensure that the liquid metal flows into the mold uniformly and smoothly, avoiding problems such as underpouring or overpouring.

Predicting and preventing casting defects

1. Defect Prediction:
   • CAE fluid simulation technology can predict a variety of conditions that may occur during the solidification process of castingsflaws, such as porosity, inclusions, cracks, etc.
   • By forecasting, it is possible to take measures in advance to prevent and reduce scrap rates.
2. Defect Analysis:
   • CAE technology can analyze existing casting defects in detail and identify the causes and influencing factors of the defects.
   • The analysis can guide subsequent process improvement and quality control to improve the overall quality of the castings.

Optimization of casting equipment parameters

1. Optimization of mold design:
   • Temperature and stress field variations during the casting process can be modeled with CAE fluid simulation techniques.
   • Through simulation, the design of the mold can be optimized to improve the service life and performance of the mold.
2. Optimization of casting process parameters:
   • CAE technology can simulate the effect of different casting process parameters on the quality of castings, such as pouring temperature, pouring speed, mold preheating temperature, and so on.
   • Through simulation, these process parameters can be optimized to improve the quality and productivity of castings.

Casting microstructure simulation

1. Microstructure prediction:
   • During the casting process, CAE fluid simulation technology can simulate the formation and evolution of microstructures, grain growth, phase transformations, and so on.
   • Through simulation, the microstructure and properties of the castings can be predicted, providing a basis for subsequent heat treatment and performance optimization.
2. Heat Treatment Simulation:
   • CAE technology can also simulate microstructural changes in austenitic, bainitic and ferritic castings during heat treatment.
   • The heat treatment process can be optimized to improve the performance and stability of castings.