O P T I M IZ E D C A S T I N G D E S I G N S

FLOW-3D Cast provides

metal casters with
highly-accurate insights
allowing you to explore
design concepts quickly
and efficiently.
Cover image courtesy of BMW Group

OP T IMIZE CAST IN G
D E SIG N S W IT H
H IG H L Y-ACCU RAT E
F IL L IN G AN D
SOL ID IF ICAT ION
SIMU L AT ION S

FLOW-3D Cast is available in three configurations,

depending on your modeling needs:
BASIC, EXTENDED, ADVANCED.

OPTIMIZED WORKFLOWS
D E S I G N F L OW

POW E RFUL SOLVE R

Intuitive interface lets users set up highly-accurate

simulations quickly and correctly.

Wide range of integrated physical models

capable of modeling casting processes
and providing solutions to filling and
solidification defects.

C L E AR M ODEL INPU T
Top-down workflow ensures that all aspects
of model setup are addressed. Models and
parameters are defined using casting terminology.

F AS T M E S H I NG
Meshing captures complex parts and molds
with minimal user input. Casting designs
can be imported and meshed in minutes.

MATE RI AL DATABASE
Material properties for alloys, molds,
cores and filters. Customizable database
with imported materials.

STREAMLINED MESHING
FOR COMPLEX PARTS
FLOW-3D Casts unique meshing methodology, FAVOR ,
handles complex geometry within a structured mesh.
FAVOR allows FLOW-3D Cast to maintain highly-accurate
flow calculations around complex geometries.
TM

This technique is referred to as free-gridding because

the mesh and geometry can be changed independently
of each other, greatly simplifying the meshing process
and saving significant time during simulation setup.
REDUCE
SETUP TIME WITH
FAVOR, OUR UNIQUE
STREAMLINED MESHING
METHODOLOGY

POWERFUL VISUALIZATION
FlowSight, an integrated state-of-the-art postprocessor,
offers powerful visualization for identifying casting defects.

Portable results
Report generation
Batch postprocessing
Multiple iso-surfaces
2D-slicing through results
Multiple views of simulation results
Simultaneous stress and fluid flow view
Extensive annotation capabilities

Read and plot data from external sources

Interactive probing
Texture mapping
Definable viewpoints
Volume rendering
Flipbook
Vent flow rates

DESIGN OPTIMIZATION

OXI DE FORM ATI ON

AI R E NTRAI NME N T

MICROP OROSIT Y

SOLIDIFICATION
AND SHRINKAGE

TH E R M A L S TR E S S

FLOW-3D Casts defect

tracking capabilities help
predict where oxides are
likely to occur during the
filling process. FLOW-3D
Cast accurately tracks
these oxides and their
final locations.

The air entrainment model

in FLOW-3D Cast is used
to estimate the amount of
entrained air that occurs in
metal casting systems during
filling. This model is an
excellent predictor
of porosity.

FLOW-3D Cast predicts

microporosity occurring
late in the solidification
stage, letting you make
design adjustments quickly,
avoiding critical
and costly defects.

FLOW-3D Cast has a

complete suite of tools
for modeling solidification
and pinpointing areas of
excessive shrinkage or
porosity, allowing you to
determine placement of
risers to assure such defects
are alleviated.

FLOW-3D Casts thermal

stress model enables you
to predict precisely where
stresses will occur and how a
casting distorts. Stresses are
simultaneously computed
in the mold and in the
solidifying metal.

D E F E C T P R E D I C T IO N

I R O N S O L I D I F I C AT I O N

C O R E G A S G E N E R AT I O N

COOLING CHANNELS

DIE EROSION

The iron solidification model describes the

eutectic and near-eutectic solidification of
cast irons capturing the formation of austenite,
graphite and carbide and the density variations
that occur during the cooling process as
these different phases form.

The core gas model predicts the effects of gas

generation during the pouring and solidification
process for resin-bonded cores. The core gas
model predicts the location and quantity of
gas defects and helps to design core venting
that will safely evacuate the binder product
gas from the cores.

Cooling channels are used in die casting

and permanent mold casting for thermal
management to prevent the overheating
of the die and to control solidification.
FLOW-3D Casts cooling channel model
includes time-dependent temperature
and heat transfer coefficients and
thermocouple-controlled activation
for cooling and heating.

One of the causes of die erosion is cavitation,

which occurs when metal pressure drops below
a critical level due to flow separation and high
velocities. This unsteady flow can be very
damaging to dies. FLOW-3D Casts cavitation
potential model helps you determine where
cavitation-induced die erosion might occur
and make adjustments before casting.

FOUNDRY APPLICATIONS

DIE CASTING APPLICATIONS

D I E C A S T I N G C O LD C HAMBER
OX I D E D E F E C T ANALYS IS
HELLEBUSCH TOOL & DIE

IDENTIFY POTENTIAL
CASTING DESIGN
ISSUES BEFORE
PART PRODUCTION

The engineering team at HELLEBUSCH TOOL & DIE ran a series of high
pressure die casting filling simulations to identify possible defects in
a steering wheel casting to see whether the casting design needed
modification. The simulation results show that the majority of the oxides
were trapped in the overflows. The top and bottom of the back of the
steering wheel indicate locations where overflows could be placed
to capture oxides to further improve the casting quality.

COURTESY
HELLEBUSCH TOOL & DIE

ACCURATELY MODEL ALL

STAGES OF HIGH PRESSURE
DIE CASTING: THERMAL DIE CYCLING,
SPRAY COOLING, SHOT SLEEVE
OPTIMIZATION, FILLING
AND SOLIDIFICATION.

HIGH P R ES S U RE DIE C AS T ING

FLOW-3D Cast provides highly-accurate solutions for die casters.

THE RMAL DI E CYCLI NG

Die cycling simulations are an essential component
for high-pressure die casting. Simulations must
provide accurate temperature distributions in a die
throughout multiple die cycles. With FLOW-3D
Cast, the temperature distributions for thermal
die cycles are calculated for solidification,
die opening, spray, air blow, and die closing.

L A D L E P O U R ING & S HO T S LE E VE
FLOW-3D Casts moving objects model accurately
captures the fluid motions throughout the process,
giving you insights from the actual ladle pour to the
fast shot. Test designs quickly by changing only a
few parameters and compare optimized results
easily with FlowSight.

Courtesy of Buhler

G R A V I T Y C A S T ING S O LU T IO NS
T E K S I D S.P.A.
Filling of a gravity casting using the Moving Objects model to
simulate a moving ladle with a prescribed motion that matches
the actual machine setup. Filters are used in the runners in order
to control the flow. The small viewport on the top left illustrates
a vertical section of the mold.

Courtesy of Teksid S.P.A.

Post processed with EnSight.

FOUNDRY
CE N T RIF U G A L C A S TI N G

FLOW-3D Cast provides highly-accurate filling

and solidification solutions for foundry processes.

The higher pressure associated with centripetal

acceleration in centrifugal castings, forces defects
towards the rotational axis. FLOW-3D Casts

G RAVI TY POUR CASTI NG

non-inertial reference frame model can prescribe

Part quality can be affected by entrainment of air

this rotation with the ability to modify its speed.

from overly-turbulent filling and by shrinkage-

This allows you to easily visualize and locate

induced defects. FLOW-3D Cast accurately tracks

potentially-costly defects.

the movement of the metal front, the location

of potential defects and the evolution of
temperatures during the filling process.
After filling is complete, the solidification
of the metal, and its resulting shrinkage,
can also be modeled.

IN VE ST ME N T CAST IN G
LO ST F OA M CA S T ING
FLOW-3D Casts special models simulate the entire
lost foam process, predicting where folds or other
defects associated with trapped foam products
are located. FLOW-3D Cast provides engineers
with the insight necessary to determine filling
process parameters, such as pour temperature
and pressure, gate sizes and locations.

FLOW-3D Casts powerful numerical models can

simulate the complex investment casting process,
allowing users to analyze wax injection, metal
filling, and metal solidification as well as accurately
predict defects. This analysis helps casting
companies improve component design,
reduce defects, and shorten development time.

NEW All-Electric Car BMW i3

B MW GROUP
Previously, structural parts in cars were made of steel metal. Several advanced
auto manufacturers have succeeded in manufacturing these parts as complex
thin-walled light metal castings that are considerably lighter than the steel
designs. This reduction in weight is especially important for electric cars that
have to carry heavy batteries. Casting such complex and large parts is a very
demanding task and requires fine tuning of many parameters such as location
and dimension of ingates, vents, overflows, shot curve, casting and die
temperatures. The use of simulation early on in development enables BMW
engineers to optimize the HPDC process so that they can produce premium
quality parts according to the specification of their new car designs.

Courtesy of BMW Group

BASI C

E XTE N DE D

A DV A N CED

All BASIC features, plus:

All EXTENDED features, plus:

Multi-block meshing, up to 5 mesh blocks

Unlimited mesh blocks for accurate

Filling, including viscous turbulence and surface tension effects

Solidification and heat transfer

Expandable database for cast alloys, molds, etc.

Chills, isolating sleeves and exothermic reactions

Temperature-dependent properties

Filters for flow control

mold temperature distribution

Sand core blowing

Track oxide formation and defects

and cooling line optimization for

Model moisture drying in molds and cores

Identify filling & solidification related porosity

temperature control

Vents

Natural convection of molten metal before solidification

Optimize shot sleeve performance

Enhanced viscous effects including

Cast iron solidification

Flow tracers

Particle modeling

and efficient simulations

Thermal- and mechanically-induced

stresses and distortions

Filling and solidification analysis for

Binary segregation

high pressure die castings

Complete sand core suite

Trapped gases and venting effects

Capture core gas release

Thermal die cycling to determine

and associated defects

and apply motion to simulations

non-Newtonian viscosity, shear thinning/

Lost foam castings and foam defects

thickening and thixotropic flows

Locate cavitation to determine where

Heating due to viscous shear

die erosion may occur

Permeable mold model for modeling

air escape during filling

Six-degrees-of-freedom motion for

prescribed shot sleeve and complex
ladle pouring motion

ALL FLOW-3D CAST PACKAGES FEATURE

H I G H LY- A C C U R AT E F L O W A N D S O L I D I F I C AT I O N R E S U LT S
A U T O M AT I C M E S H I N G F O R E A S Y M O D E L S E T U P
M AT E R I A L L I B R A R I E S F O R M E TA L S , M O L D S , F I LT E R S A N D R I S E R S

FLOW-3D CAST PACKAGES ARE AVAILABLE

A C T I V E S I M U L AT I O N C O N T R O L

WITH ESCALATING LEVELS OF MODELING POWER:

F LO W S I G H T P O S T P RO C E S S O R

BASIC, EXTENDED and ADVANCED.

LEARN MORE
F LO W 3 D .C O M /C A S T

SUPPOR T

C O MPA N Y

Flow Sciences team of highly-experienced CFD support engineers prides itself on offering same day,

In 1963, while at the Los Alamos National Laboratory,

expert support by phone, email and live chat for the metal casting industry. Our dedicated support

Dr. C. W. Tony Hirt pioneered several landmark fluid

team is committed to the timeliness of your projects and successful implementation of FLOW-3D Cast.

dynamics methods, stability enhancing procedures

and a unique free surface tracking techniquethe

USE R S S ITE

Volume of Fluid or VOF method. In 1980, Dr. Hirt left

LANL to form Flow Science, Inc., with the mission to

Explore a variety of resources on the Users Site, such as:

develop a new generation of fluid dynamics modeling

Metal casting CFD checklists

capabilities for industrial and scientific applications.

Live chat

Example simulations

Flow Science now supports a worldwide customer base

Software updates

of commercial, academic and government users.

FAQs, validations and hints & tips

Our staff of scientists and engineers constantly

Presentations, workshops and tutorials

strives to make innovative and useful improvements

to our product suite.

In order to access the Flow Science Users site, you need an active license and maintenance contract.

T R AINING
Flow Science offers comprehensive training classes for FLOW-3D Cast in Santa Fe, NM.
The 2-1/2 day training classes give attendees a solid, working understanding of the software
as well as hands-on experience with real-world simulations. We encourage potential users in addition
to new and existing users to attend. One-on-one consultation is available; please call for details.

683 Harkle Road

Santa Fe, New Mexico 87505
(505) 982-0088
sales@flow3d.com

LEARN MORE
F LO W 3 D .C O M /C A S T

F LO W - 3 D C A S T
IS A PRODUCT OF
F LO W S C I E N C E .
MADE IN THE USA.

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F LO W 3 D .C O M /C A S T