Experience of sample trial production in traditional casting is accumulated from repeated sample-making-process one after another. For a long time, most have relied on experience and data from actual samples development as technical support, and there has been a lack of a set of professional and effective methods and means. In recent years, with the application of simulation software, it can predict possible defective parts of products by controlling the design and manufacturing process, effectively reducing the probability of defects and becoming the best solution to avoid defects.
At present, the simulation software application environment is very mature, and various types of simulation software are gradually becoming more and more perfect, and play a huge role in various industries, for example casting industry, such as sand casting, lost foam casting, die casting, low pressure casting, investment mold Casting, centrifugal casting, continuous casting and other casting processes.
At present, product requirements are getting higher and higher, and manufacturing processes are becoming more and more complex. Simulation application is one of the most effective control methods to reduce trial production costs. It can effectively reduce the proportion of actual trial production times, reduce design blindness, save design costs and trial production expenditure shortens the engineering cycle and improves the success rate of trial production.
ESI Group's ProCAST is one of the industry's leading casting process simulation software. Based on its powerful finite element solver and advanced options, it provides efficient and accurate solutions to meet the needs of the foundry industry, discarding the traditional error-revision approach. So to speak, ProCAST is the perfect solution to reduce manufacturing costs, shorten development time and improve process quality.
ProCAST software can not only lift product design and process levels in the short term. In the long run, the traditional model of the foundry industry can be changed and the overall level of casting can be improved.
Before using mold software, relying solely on experience and repeated trial production, trial production investment would be expensive and the trial production cycle would be too long. It also affects product costs and delivery time, which is very detrimental to the company and customers.
After the introduction of simulation software, the product yield rate can be improved, the production cycle can be shortened, labor productivity can be effectively improved, and it can also help reduce the labor intensity of workers.
We can scientifically and intuitively describe and record casting technology and experience, turning past abstract experiences into simple and clear paper documents for documentation, which is conducive to the continuation of casting technology and resource sharing.
Therefore, the introduction of good casting simulation software is very necessary and will greatly promote the development of casting technology.
Using this superior simulation software, casting engineers can predict the flow field, temperature changes and stress during the formation process of castings, and also optimize design process parameters and process plans for castings. It can simulate the flow direction of molten steel during the metal filling process, display the locations of insufficient filling, air entrapment and hot nodes in certain locations, and measure shrinkage cavities, shrinkage porosity locations and microstructure changes in castings, all of which allow designers to understand and control the feasibility of process solutions and provide customers with forward-looking solutions.
Bo Wang Head of Engineering Team
December 22, 2023