ProCAST can simulate and analyze almost any problems that may occur in the production process of sand casting. It can analyze shrinkage, cracks, air entrapment, sand flushing, cold shuts, insufficient pouring, stress, deformation, mold life, process development and repeatability. It provides foundry engineers with a new way to study the sand casting process, so that they have the opportunity to see what happens in the mold cavity, thus generating new design solutions. The results can also be displayed in the web browser, so that the more complex sand casting process can be discussed and studied through the Internet.
Shrinkage cavity
Shrinkage is caused by the liquid can not be effectively fed from the gating system and riser during the solidification shrinkage process. Due to the insufficient feeding of the riser, large internal shrinkage defects are caused. ProCAST can confirm the position of the closed liquid.
Crackle
Sand casting is prone to produce hot cracks during solidification and even cracks during subsequent cooling process. Using thermal stress analysis, ProCAST can simulate cracks during solidification and subsequent cooling process. Before actual production, these simulation results can be used to determine and test various designs to prevent defects.
Air wrapping module
Bubbles and oxide inclusions produced by liquid filling obstruction will affect the mechanical properties of sand castings. Turbulence in the filling process may lead to the generation of oxide inclusions. ProCAST can clearly indicate the presence of the flow, and the location of these defects can be displayed and tracked on the computer. It is easy to design the gating system and reasonably arrange the air holes and overflow holes because it can directly monitor the running track of the entrapped air.
Sand washing
In sand casting, sometimes sand flushing is unavoidable. If sand washing occurs at the key part of sand casting parts, it will affect the quality of sand casting. ProCAST can confirm the production of sand washing through the analysis of velocity field and pressure field, and can easily confirm the final sand inclusion area through virtual particle tracking.
Cold shut and insufficient pouring
In the process of casting and molding, some improper process parameters, such as cavity supercooling, pouring speed too slow, liquid metal temperature too low, will lead to some defects. Through the coupling calculation of heat transfer and flow, the designer can accurately calculate the change of liquid temperature during the filling process. During the filling process, the solidified metal will change the flow form of liquid in the filling process. ProCAST can predict the problems occurred during the filling process of sand casting, and can then quickly develop and verify the corresponding improvement plan.
Life of die casting die
Thermal cycle fatigue will reduce the service life of the die-casting die. ProCAST can predict the stress cycle and maximum compressive stress in the die-casting die. Combined with the corresponding temperature field, it can accurately predict the key parts of the die and optimize the design to extend the service life of the die-casting die.
Process development and optimization
After the market positioning of new products, the development and optimization of production lines should be started. ProCAST can test various innovative designs to optimize them, greatly reducing the process development time and minimizing the cost.
Repeatability
Even if a process has been running smoothly for several months, accidents may occur. Due to the variety and mutual influence of sand casting process parameters, it is impossible to continuously monitor all parameters for a long time in actual operation. ProCAST allows casting engineers to quickly and quantitatively check the impact of each parameter, so as to determine the range of parameters in order to obtain repeatable, continuous and stable production.