Design and Simulation of Casting Processes

Our Design & Simulation Process

Advanced Simulation Technologies

Our design and simulation team utilizes the latest computational tools to model and optimize casting processes before physical implementation. This approach allows us to identify and address potential issues early in the design phase, resulting in significant time and cost savings.

Our simulation capabilities include:

• Computational Fluid Dynamics (CFD) for melt flow analysis
• Solidification simulation to predict microstructure development
• Thermal analysis to optimize cooling and solidification times
• Stress and distortion analysis to predict dimensional accuracy
• Defect prediction (porosity, shrinkage, inclusions)
• Gating and riser system optimization

Simulation Software Expertise

Our engineers are proficient in multiple industry-standard simulation software packages, allowing us to select the most appropriate tools for each specific application:

ProCAST

High-fidelity simulation of casting processes with advanced capabilities for complex geometries

MAGMASOFT

Comprehensive simulation suite for foundry processes with integrated optimization

FLOW-3D Cast

Specialized in high-precision fluid flow modeling for casting applications

ANSYS Mechanical

Advanced structural analysis for predicting service performance of cast components

Design Optimization Process

Our approach to design optimization follows a systematic methodology:

1. Initial Design Analysis

Evaluation of component function, required properties, and manufacturing constraints

2. Material Selection

Identification of optimal material composition based on performance requirements

3. Process Simulation

Computer modeling of filling, solidification, and cooling processes

4. Defect Prediction

Analysis of potential quality issues based on simulation results

5. Design Iteration

Refinement of component design and process parameters based on simulation feedback

6. Final Validation

Comprehensive simulation of optimized design to verify performance

Case Studies

Automotive Engine Block Optimization

An automotive manufacturer was experiencing high rejection rates in their V6 engine block casting process due to porosity issues in critical areas. Our simulation team identified suboptimal gating and feeding designs causing turbulent flow and entrapped gases.

Result: Our redesigned gating system reduced porosity defects by 78%, leading to a 15% improvement in overall yield and annual savings exceeding $850,000.

Power Generation Turbine Component

A power generation equipment manufacturer needed to optimize a complex turbine component with tight dimensional tolerances. Our simulation-driven approach identified optimal process parameters and implemented strategic cooling to control solidification patterns.

Result: Dimensional variation was reduced by 65%, while simultaneously reducing production cycle time by 22%, allowing the client to meet challenging delivery schedules.

Benefits of Our Simulation Approach

Cost Reduction

Minimize expensive physical trials, reduce material waste, and optimize production efficiency

Reduced Time-to-Market

Accelerate development cycles by identifying optimal designs earlier in the process

Quality Improvement

Predict and eliminate potential defects before production begins

Innovation

Safely explore novel designs and processes without the risk of physical trials

Design & Simulation Applications

Our design and simulation services are applicable across numerous industries and casting methods:

• Sand casting for large components in heavy equipment and marine applications
• Die casting for automotive and consumer product components
• Investment casting for aerospace and medical components requiring high precision
• Continuous casting for high-volume production
• Specialized processes such as lost foam and ceramic shell casting

Ready to optimize your casting process?

Contact us today to discuss how our design and simulation expertise can help you improve quality, reduce costs, and accelerate your component development. Our team is ready to bring the power of advanced simulation to your casting challenges.

Contact Our Team