AnyCasting

CASTING SIMUALTION SOFTWARE: ANYCASTING

At Simuace Solutions, we proudly offer AnyCasting, a powerful and intuitive casting simulation software developed to support foundries, design engineers, and manufacturers in achieving flawless casting performance across various processes and materials.

Sand Casting

Simulation tools within AnyCasting allow for the detailed analysis of mold filling, solidification behaviour, and potential defect formation in sand casting processes, considering factors such as molten metal properties, sand systems, and gating design etc. This enables foundries to optimize their sand-casting techniques for various part geometries and alloy systems.

High Pressure Die Casting (HPDC)

AnyCasting offers specialized modules to simulate the high-velocity injection of molten metal into permanent molds under high pressure. This includes the prediction of common HPDC defects like gas entrapment, porosity, and cold shuts, as well as the optimization of shot parameters, gate design with PQ2, and die temperature control. It can also simulate Counter Pressure Casting (CPC).

Low Pressure Die Casting (LPDC)

The software facilitates the simulation of molten metal filling permanent molds under controlled low pressure. This enables the analysis of filling patterns, solidification progression, and the prediction of defects such as shrinkage and porosity, aiding in the optimization of pressure cycles and gating systems for LPDC applications.

Investment Casting

AnyCasting enables the simulation of the intricate multi-step investment casting process, from mold filling of the ceramic shell to the solidification of the cast part. This includes the prediction of defects related to shell integrity, metal flow in complex geometries, and solidification patterns, supporting the production of high-precision components with excellent surface finish.

Gravity Die Casting (Metal Mold Casting&Tilt Pouring)

AnyCasting supports the simulation of gravity-fed casting into reusable metal molds. This allows for the analysis of filling behaviour, solidification rates influenced by mold materials and preheating, and the prediction of defects like misruns and shrinkage, assisting in the design of efficient gating and venting systems.

Centrifugal Casting

AnyCasting includes capabilities to simulate the unique aspects of centrifugal casting, where molten metal is poured into a rotating mold. This allows for the analysis of metal distribution under centrifugal forces, prediction of segregation and porosity influenced by rotation speed and cooling, and optimization of process parameters for producing high-density, cylindrical or near-net-shape components.

Ingot Casting

The software provides tools to simulate the solidification of large metal ingots, considering factors such as cooling rates, segregation phenomena, and the formation of macrostructural defects. This aids in the development of optimized ingot casting practices to ensure material homogeneity and quality for subsequent processing.

AnyCasting simulation software provides a comprehensive suite of output results designed to give users a detailed understanding of the casting process and enable them to optimize their techniques. These results can be broadly categorized as follows:

Multiple Window Options: Offers various windows for Pre-setting, Post-results, solver etc to use efficiently and computational efficiency for multiple projects.
Fixed Mesh, Variable Mesh: Supports both uniform (fixed) meshing for general analysis and adaptive (variable) meshing to refine the mesh in critical areas with high gradients (e.g., near complex features or where defects are likely).
Filling Time Analysis: Predicts the time it takes for the mold cavity to fill with molten metal, crucial for optimizing gating design and preventing filling-related defects.
Air Entrapment Prediction: Identifies areas where air or gases might become trapped in the mold cavity during filling, leading to porosity or other defects.
Velocity Field Visualization: Shows the speed and direction of the molten metal flow during the filling process, helping to identify areas of turbulent or stagnant flow.
Pressure Distribution Analysis: Predicts the pressure of the molten metal within the mold cavity during filling, important for mold design and preventing mold deformation.
Cooling Rate Analysis: Calculates the rate at which different parts of the casting cool down, influencing microstructure and residual stresses.
Solidification Time Analysis: Calculates the time required for different sections of the casting to solidify, essential for understanding microstructure development and potential shrinkage issues.
Thermal Modulus: Predicts the thermal behaviour of the casting during solidification, aiding in the design of effective gating and risering systems to prevent shrinkage defects.
Shrinkage Prediction: Provides detailed analysis of potential shrinkage, including the predicted volume of shrinkage, its size, and its location within the casting.
Misrun Prediction: Identifies areas where the molten metal may fail to completely fill the mold cavity, allowing for adjustments to gating design and process parameters.
User-Defined Result Outputs: Allows users to define and extract specific data or calculations based on their particular analysis needs.
Microporosity (SIGAP-Shrinkage induced gas porosity): Directly predicts the formation and distribution of gas /shrinkageporosity within the casting.
Comparison Tools: Enables the comparison of simulation results across different design iterations or process parameters.
AnyPost, PPTX Report, Real post to PowerPoint: Facilitates post-processing of simulation results through AnyPost, and enables the generation of comprehensive reports in Microsoft PowerPoint format for easy sharing and presentation.

Some Specific Outputs of AnyCasting

Gas Analysis

- Gas Pressure: Predicts the pressure of trapped gas within the casting.
- Gas Amount: Quantifies the volume of trapped gas.
- Oxide Tracing: Tracks the formation and movement of oxides during the filling process.
- Inclusions: Predicts the location and distribution of inclusions within the casting.
- Leak Prediction: Identifies potential areas of leakage due to porosity or other defects.

Shot Sleeve Optimization

- Optimization of transition from low to high speed: Provides insights for optimizing the plunger speed profile to minimize air entrapment.
- Cold flakes: Predicts the formation of cold flakes due to premature solidification.

Vaccum Application

- Application of Vacuum: Allows for the simulation of vacuum-assisted die casting and its impact on defect reduction.
- Vacuum equipment: Provides data related to the effectiveness of vacuum equipment parameters

Die Life

- Die Soldering: Predicts areas prone to soldering between the casting and the die.
- Mold Erosion: Estimates the potential for erosion of the die cavity.

Cooling System Analysis

- Channel cooling and heating: Evaluates the effectiveness of cooling and heating channels in the die.
- Conformal Channel: Simulates the impact of conformal cooling channels on temperature distribution.
- Spot Cooling: Analyzes the effect of localized spot cooling techniques.

Cast Iron Specific

- Inoculant effect: Simulates the influence of inoculants on microstructure formation.
- Mold Strength: Predicts the strength of the sand mold.
- Microstructure: Predicts the distribution and phases of the cast iron microstructure (e.g., Perlite, Ferrite, Carbide).

Solidification Specific Results

- Shrinkage: Predicts the casting shrinkage
- SIGAP: Predicts the Shrinkage Induced Gas Porosity
- Niyama Parameter: Predicts the Niyama Parameters results
- Modulus: Predicts the Casting modulus, thermal modulus etc

Other Outputs

- Oxide and Slag Inclusion: Predicts the formation and location of oxide and slag inclusions.
- Database of Exothermic Sleeve, filter etc: Utilizes databases of exothermic sleeves and filters in the simulation to analyze their impact on the casting process for sand casting process
- Shell Filling: Simulates the filling of the ceramic shell mold, predicting potential defects such as incomplete filling or turbulent flow in Investment Casting
- Metal Temperature Distribution: Simulates the temperature distribution of molten metal under various conditions, predicting temperature drop with respect to time.
- Hot Tearing: Analyzes the potential for hot tearing during the solidification of the ingot.
- Turbulence Front: Tracks the movement of the metal filling considering the turbulence and wall adhesion.
- Air Gap Formation: Simulates the formation of air gaps between the casting and the mold, affecting heat transfer.
- Mold Temperature: Predicts the temperature distribution within the metal mold during the casting process.
- Metal Velcoity, Pressure etc

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