There are many software for casting simulation, such as FLOW-3D, MAGMAsoft, ProCAST, Huazhu CAE, etc. Casting simulation is carried out by ProCAST software. As the flagship product of ESI group’s thermophysical comprehensive solution, ProCAST is the most integrated of all casting simulation software. It takes the lead in using the most advanced finite element technology in commercial software, and is equipped with powerful data interface and automatic meshing tools. With the help of ProCAST system, the casting engineer may simulate the flow field, temperature field and stress field during the formation of cast steel joints and predict the quality of castings before completing the preparation of casting process. On this basis, the casting equipment parameters and process scheme are optimized. ProCAST can simulate the flow process of metal casting, accurately display the positions of insufficient filling, cold lap, air entrapment and hot spot, as well as residual stress and deformation, and accurately predict the changes of shrinkage cavity, porosity and microstructure in the process of casting.
ProCAST software uses finite element numerical method to calculate heat transfer, punch flow process and thermal field coupling stress
The main features of force field calculation, microstructure simulation and shrinkage porosity prediction simulation are as follows:
(1) All modular design, suitable for the simulation of most casting processes;
(2) Using the finite element technology, the casting solidification process can be fully coupled with heat flow stress, and there is no need to connect with the third part
The results of coupling calculation by three-party software are more accurate;
(3) More accurate geometric description has more advantages for thin-walled parts and complex shapes, and can better deal with flow
Question. It is especially suitable for complex castings such as cylinder head, cylinder block, clutch housing and gearbox housing;
(4) CAD / CAE is highly integrated, which can directly read mainstream software data and has powerful geometric repair function;
(5) It is suitable for centrifugal casting, inclined casting, precision casting, die casting, continuous casting, etc. numerical simulation can also be carried out for some special process measures, such as filter screen, thermal insulation riser sleeve, etc.
ProCAST carries out casting simulation calculation, including the following basic steps: generating finite element mesh model, setting calculation parameters, simulation calculation and displaying calculation results.