New Version of FLOW-3D Cast Aims to Simplify Simulation Workflows

Traditionally, casting simulations have been a complex task due to the involved physical process and the variables represented by each phase of the process. A new release of FLOW-3D Cast aims to simplify the performance of these types of simulations with enhancements that promise to make the simulation process easier and more accurate.

Interface

Casting simulations have numerous steps and plenty of elements involved in the actual casting process. For that reason, FLOW-3D Cast features a new interface that FLOW-3D Cast maker Flow Science is calling the “What You See Is What You Need,” or WYSIWYN, interface.

The design methodology of WYSIWYN places the most important information an early level in the modeling in the hopes that it will make it easier for users to find the information they need and to make adjustments, if needed.

Another feature of the WYSIWYN interface is that it remains consistent as users step through different phases of the simulation, meaning that the information is presented in a similar layout regardless of which phase the user is working on.

The new user interface gives user access to key information. (Image courtesy of Flow Science.)

Process-Oriented Workspace

Along with the enhancements to the user interface and the effort to provide users with the information they need, FLOW-3D Cast v4.2 also introduces a process-oriented workspace. The workspace aims to guide users through the stages of high-pressure die casting process, including thermal die cycling, filling, solidification and cooling. The context-sensitive interface recognizes each sub-process simulation and fills in required and best practice settings.

Flat-panel GUI gives access to frequently used commands. (Image courtesy of Flow Science.)

Die Spray Cooling Model

The die spray cooling model, developed in cooperation with auto maker Audi AG, gives users the ability to represent all facets of die preparation, including the shape of the mold surface and the position and movement of the spray nozzles.

Spray cooling model developed in collaboration with Audi AG. (Graphic courtesy of Audi AG.)

For example, an individual spray can be modeled and assigned movement. To accurately predict the temperature distribution in the die across the spray cooling phase, the spatial variation in the spray applied to the die should be modeled. The die spray cooling model explicitly computes the cooling from each spray, instead of using a constant heat transfer coefficient across the entire die cavity. This will allow users to see the influence of each spray in the final result

Further details of all the enhancements can be found on the FLOW-3D Cast website.