Casting Simulation
EVERGREEN has officially licensed Casting Simulation software that can simulate all materials and casting processes.
Entrust your casting projects to EVERGREEN, and we can help you optimize and improve product design, mold design, and processes, effectively enhancing product quality and reducing defect rates.
EVERGREEN's Casting Simulation
What is Casting Simulation?
Casting simulation is a technology that uses computer software to simulate, analyze, and predict the flow, filling, solidification, and cooling processes of molten metal in a mold cavity during casting, as well as any defects that may arise during these processes.
In simple terms, it is a “virtual” casting process performed on a computer, allowing you to see how the molten metal flows and solidifies in the mold, as well as any potential issues that may arise, before actually opening the mold and pouring the metal.
It can help us effectively reduce manufacturing costs and improve product quality.
What Problems Can Casting Simulation Help You Solve?
Optimize mould design (especially the pouring system):
- It is possible to predict how metal solutions fill cavities.
- It is possible to identify areas where turbulence, gas entrainment, and oxidation slag occur, guiding us in making improvements.
- The position, size, and number of gates, as well as the design of the sprue, cross sprue, and straight sprue, can be optimized to ensure smoother, faster, and more orderly filling.
- The reasonable position, size, and shape of the riser can be determined to ensure effective shrinkage prevention.
- Optimize the position of the exhaust channel to ensure that gases can be discharged smoothly.
Predicting and Reducing Casting Defects:
- Shrinkage/Shrinkage Porosity: Simulates the solidification process and can predict the location and size of pores caused by liquid shrinkage and solidification shrinkage.
- Pores/Gas Entrapment: Predict the location of pores caused by gas entrapment, poor exhaust, or sand gas emission.
- Cold Shuts/Insufficient Casting: Predicts areas of incomplete fusion or insufficient filling due to low metal solution temperature, slow flow rate, or excessive process length.
- Hot Cracking: Analyze thermal stresses and deformation during solidification and cooling, and predict areas where cracks may form.
- Inclusion/Impurity: Simulates the position where slag or oxides are entrained in the metal stream and remain.
Optimize process parameters:
- The effects of different pouring temperatures and pouring speeds on filling and solidification can be evaluated.
- Analyze the effects of mould temperature and cooling conditions (such as cooling channel design) on solidification rate and defect formation.
- Predict the solidification time and total production cycle of castings.
Predicting the Final Quality of Castings:
- Simulate the formation of microstructures (such as grain size).
- Predict residual stresses and deformation (warping) in castings.
- Evaluate material properties (such as hardness and strength) at different locations.
Some advantages of 3D scanning
Improve Casting Quality
Predict all possible problems during the design phase and eliminate the root causes of defects in a timely manner. Improve casting quality and reduce the rate of defective products.
Shortening Development Cycles
Casting simulation can reduce or even eliminate the need for physical testing, allowing multiple simulations with different parameters to be conducted directly on a computer.
Lower Development Costs
You can perform simulations directly on your computer to identify issues, thereby saving costs associated with mold modifications, material waste, trial mold machine time, and labor costs.
Innovative Design
Provide a basis for mold design for complex, thin-walled, and high-precision castings, and design more efficient pouring and gating systems.
Choose EVERGREEN as Your Partner
Entrust your casting project to EVERGREEN, and you will experience the professional services we provide. We will regularly update you on the progress of your project, help you find the most suitable manufacturing process for your parts, and identify the most cost-effective methods. We never delay delivery schedules; in fact, we typically complete production five days ahead of schedule.
Casting Simulation
Aluminum Alloy High-Pressure Casting
Sand Casting
Investment Casting
