2024 Best Metal Casting Simulation Software List

Best Metal Casting Simulation Software List

ProCast
Flow-3D
MagmaSoft
NovaCast
AnyCastSoftware
TherCast By TransvalorAmericas

ProCast

What casting process does FLOW-3D software simulate?

Pro-Cast software is used for the following casting process simulation:

High-pressure die-casting process (HPDC)
Low-pressure die-casting process (LPDC)
Hot chamber die-casting process
Cold chamber die-casting process
Permanent mould casting process
Vacuum die-casting process
Gravity die-casting process
Rotacast casting process
Tilt casting process
Counter-pressure casting process
Precision casting process
Stainless steel casting
Aluminium casting

ProCast Benefits, Features And Software Application

The benefits of using Procast casting software in the manufacturing industry are as follows:

Procast is capable of giving results in a short time saving time and resources for the foundry.
Improve the dimensional, geometrical and surface accuracy of the final casting.
Improves the efficiency of the casting process and optimizes the cycle time of the casting production cycle.
Identify and detect shrinkage porosity and weaker casting sections in the given casting.
Able to detect the flow of molten metal in the small sections of the die mould to eliminate any early casting solidification.
Engineers can optimize the flow of molten metal, directional solidification, reduce defects and improve the quality of the final casting.
Able to design proper riser, sprue, runner, chills and mould cavity for the highest quality excellent casting production.
Better simulation improves the final product in terms of mechanical properties, reduces defects and increases the production rate of the foundry.
Able to detect misrun, cold shunt, insufficient molten metal, air in the mould, heat loss, porosity, and air trapped inside the sleeve during the casting process.
Gives simulation with a casting process that utilizes cores, exothermal materials and insulation.
Has a good materials database for metals such as zinc, cast iron, aluminium, magnesium, nickel and copper.
Reduces the erosion of the sand mould by giving accurate data about the flow of the molten metal in the sand mould.
Improves yield of the casting process increasing the profitability of the foundry.
Identification, prediction and analysis of oxide layers, location and movement of the oxides in the final casting.
This software is used in simulation of investment casting simulation, die casting simulation and tilt casting simulation.

FLOW-3D

What casting processes does FLOW-3D software simulate?

FLOW-3D software is used to stimulate the following casting process simulation:

Investment casting process
Sand casting process
Gravity die-casting process
Die casting process
Low-pressure die-casting process
High-pressure die-casting process
Gravity die-casting process
Continuous casting process
Centrifugal casting process
Tilt pour casting process
Sand core making

FLOW-3D Casting Simulation Software Benefits, Advantages, Features, Capabilities And Software Application

The benefits of using FLOW-3D metal casting simulation software in the manufacturing process are as follows:

Analysis of time, temperature gradient, molten metal flow, flow path, particle tracer, turbulence, shrinkage, high pressure (HPDC), low pressure (LPDC), mould erosion, pour control and premature casting solidification in thinner sections of die cavity.
Analysis of dynamic casting simulation, ladle pouring, ladle motion, thermal analysis, defects prediction, sand cores, vacuum in mould, probe placement, investment casting shell mould creation, nest meshing, simple meshing and multi-block meshing possible.
In investment casting components analysis of shell filling, formation, solidification, cooling and heat transfer in shell for multiple cavity mould section.
In the sand casting process, this software helps engineers eliminate excess moisture during the final sand casting process, and decide the appropriate location of in-gate and vents.
Serves engineers to decide the proper placement of sand cores to produce the desired cavity in the final sand casting process.
This software helps with the proper selection of exothermic material, sleeve, insulation, chills, padding and exothermic riser assembly.
Analysis of centrifugal casting process types such as horizontal centrifugal casting, sem-centrifugal centrifugal casting, centrifuge centrifugal casting and vertical centrifugal casting for ladle pouring, defects, thermal analysis, superheat, advanced solidification process, defect predictions, convective and radiative heat transfer rate, rotation of the true centrifugal casting mould, turbulence during metal spinning, helps engineers decide the selection of appropriate metal, mould and spin rate for the moulding process.
Analysis of thermal modulus, mould rotation and velocity, thermal gradient cycle, reverse tilt pour and pouring in tilt pouring casting process.
Analysis of the thermal stress induced at the metal mould, pouring rate of metal from tundish into the mould, the flow rate of metal and billet while pouring and cooling of mould, turbulence during the mould filling operation, billet temperature analysis during the solidification of casting near the mould wall and heat transfer between mould, billet and rollers are analyzed in continuous casting processes such as direct continuous casting process and direct chill continuous casting process while producing billets, blocks, strips and sheets.
Analysis of the back pressure induced during the shot in the high-pressure die-casting process while the sleeve pushed the molten metal into the die cavity.
Able to detect hotspots, heat saturation, venting cold spots, cold shuts, voids and uneven heat distribution in the metal die and sand mould.
Gas, porosity (macro and micro) and entrapped air pockets formed during the casting process forming blow-hole defects, pinhole defects and open hold defects in the casting process.
Can calculate surface oxide, area and loss coefficient.
LES and RNG turbulence model software.
Modelling spray path for cooling die cavity and die vents in die casting process.
Simulation of mould filling, molten metal velocity in the mould, flow rate during the entry of the mould cavity at gates, metal solidification rate and gate tracer.
Prediction of microstructure, surface casting defects, porosity, oxides, air pockets, gas defects, uneven cooled sections and mechanical properties of the final casting.
Able to do a side-by-side comparative analysis of the casting components comparing the time for filling, defects, oxides and casting components analysis.
Able to cast simulations for complex components such as turbines in the investment casting process.
Provides high-quality plots, multi-view points, volume rendering, 3D, 2D and plots for better calculation and visual analysis of the casting components.
This software has applications in the design of crankshafts, engine parts and turbocharger components.
A better location for chills, risers, exothermal material and padding can be selected increasing the efficiency of the casting process.
This casting simulation software is used for simulating the investment casting simulation, sand casting simulation, die casting simulation, centrifugal casting simulation, tilt casting simulation and continuous casting simulation.

Magmasoft

What casting processes does Magmasoft software simulate?

Magmasoft software is used for the following casting process simulation:

Investment casting process
Continuous casting process
Die casting process
Mould and core design
Casting iron casting process
Steel casting process
Non-ferrous metal casting process

Magma Software Function, Advantages, Capabilities And Application In Casting Simulation

Magmasoft can optimize gating system design that includes sprue, runner, riser, runner and in-gates ensuring proper flow of molten metal into the mould cavity (sand mould or die mould)
Engineers can design dies to manufacture sound-casting at the highest quality.
Gating channels in die-casting process can be designed keeping in mind defects such as cold shut, hotspot, porosity, inclusions, misrun and poured shot.
Appropriate injecting and squeeze pressure can be selected keeping in mind back pressure, die cavity, small sections in the high-pressure die casting mould,
Thermal efficiency, thermal gradient, distortion, heat dissipation during cooling, heat distribution, hot pockets and cold sections can be identified in the mould during mould design.
Analysis of the shot chamber, die cavity filling, turbulence, thermal gradient change and time can be studied for better casting efficiency.
Changes in the temperature of the die during spraying, die soldering, vacuum in the die, negative pressure induced, air trapped, solidification time and molten metal bubble formation can be analyzed in the casting process.
The location of the core, core prints, inserts, padding and bouncy of the core during mould filling, and chills can be appropriately selected using this metal casting simulation software.
Reduces excessive trails in mould and core design saving cost, time, energy and foundry resources.
Analysis and prediction of hot tearing, slag, cracks, segregation, oxide formation, exothermic and riser location, gate design, inclusions, thermal gradient analysis, cold shut and shrinkage can be determined in the ingot casting process.
Analysis of proper heat transfer rate for the thin ceramic shell, molten metal filling the shell, the strength, porosity, thermal properties, and micro shrinkage of the ceramic shell.
This casting simulation software is used for simulating casting simulations such as investment casting simulation, die casting simulation and continuous casting simulation.

NovaCast

What casting processes does NovaCast software simulate?

NovaCast software is used in the following casting process simulation:

High-pressure die casting process (HPDC)
Low-pressure die casting process (LPDC)
Semi-solid casting process
Investment casting process
Centrifugal casting process
Gravity die-casting process
Permanent mould casting process
Lost-wax casting process
Sand casting process

NovaCast Software Capabilities, Advantages, Use And Application In Casting Simulation

NovaCast is a metal casting simulation software that helps reduce casting rejection due to casting defects, improves productivity and efficiency of casting production, saves resources for the foundry and increases profitability.
This software can analyse mould filling time during the casting process, air pocket, location of the vents, gas entrapped in the mould cavity and gating system, and backpressure induced during the die-casting process.
Quality-related issues can be solved by using NovaStress which is integrated with NovaFlow&Solid which is excellent in predicting defects due to internal stresses in the mould and casting material. NovaSress also gives insight into distortion, warpage, hot cracks and cold cracks induced in the final casting and mould during the die casting process (HPDC and LPDC), centrifugal, gravity, investment, permanent, sand casting and lost wax casting process.
NovaCast has NovaOneHPDC that can simulate the cold chamber die-casting process and hot chamber die-casting process along with an automated meshing technique.
NovaFlow&Solid is excellent in increasing the profitability of the foundry by optimizing the use of resources and casting materials, increasing the geometrical accuracy of casting, reducing waste, improving the feeding system, increasing the casting yield, and increasing the producing efficiency and casting manufacturing production process.
This casting simulation software is used for simulating the following castings simulation investment casting simulation, sand casting simulation and centrifugal casting simulation.

NovaCast software uses Magma modelling software such as NovaGating, NovaMethod and NovaFeed that refines the casting simulation process.

Casting simulation software already launched and available on the NovaSoft site are NovaStress, NovaOneGravity, NovaOneHPDC and NovaFlow&Solid which are excellent for casting simulation of various casting processes.

AnyCasting

What casting processes does AnyCast software simulate?

AnyCasting process is used for the following casting process simulation:

Ingot casting process
Low-pressure die-casting process
High-pressure die-casting process
Vacuum die-casting process
Hot and cold chamber die-casting process
Investment casting process
Sand casting process

AnyCasting Software Advantages, Benefits, Application And Features

Able to identify leakage in the casting product using the leak detection analysis in software.
Analysis of gas pockets formation, shrinkage of molten metal (macro and micro), changes in pressure and formation of oxides during the casting processes.
Analysis of vacuum pressure, detection of excess vacuum, leakage, vacuum volume, mould condition during vacuum and flow of molten metal during operation in vacuum die casting process.
Shot chamber sleeves can be designed based on the molten metal turbulence, gas formation, mould filling, incomplete filling and incomplete solidification.
Analysis of mould erosion, selection of approval location of the gate for molten metal entry to eliminate erosion, reduction in turbulence at the entry of the mould cavity, sand inclusions, slag formation, sand drop, gas around gas, penetration of molten metal and gas in the mould, gas tracing, type of microporosity, mechanical properties and the best location for core in the sand mould in the sand casting process.
Analysis of the die-casting cycle, solidification process, hot spots, cold spots and soldering in the die-casting process.
This software can help founded engineers design proper gates, runners and risers to provide directional solidification to manufacture high-quality defect-free casting.
Selection of proper location of squeeze pin, ejector pin and deformation in the casting during the ejecting operation during the metal casting process.
This casting simulation software is used for simulating the investment casting simulation, sand casting simulation and die casting simulation.

TherCast By TransvalorAmericas

What casting processes does TherCast software simulate?

TherCast simulation process is used for following the casting process:

Tilt casting process
Sand casting process
Centrifugal casting process
Ingot casting process
Investment casting process
Continuous casting process
High-pressure die-casting process
Low-pressure die-casting process
Shell mould gravity casting process

TherCast Software Advantages, Benefits, Application And Features

TherCast software reduces thermal stress, internal cavities, poured shot, misrun, metal penetration, blowholes, cold shut, warpage, the mismatch between the cope and drag section of the mould, hot tears and shrinkage during solidification operation during the sand casting process.
This software can improve continuous casting process efficiency, reduce casting rejection, increase the productivity of the foundry, improve safety, reduce bulging, improve mould filling efficiency, casting product microstructure, mould thermal gradients for allowing the metal to solidify around the mould, improve the position of rollers, nozzle, tundish and reduce the tearing and cracking of casting billets passing through the supporting rollers and cooling copper mould.
TherCast software increases the material efficiency, reduces scrap rate, increases tolerance and surface finish of casting, metal feeding, ability to produce complex intricate casting, directional solidification with refined grain structure and increases final casting yield investment casting process.
Software analysis of the mould filling flow rate, the temperature gradient of mould during the mould filling, tilt angle and impact on the mould filling, solidification rate during casting operation, turbulence and volume of metal in the mould cavity and impact on the final casting structure in the tilt casting process.
Analysis of pressure and impact on the metal flow, turbulence, ability to produce casting with complex structure, optimizes casting pressure (low and high) based on the type of casting to be produced, heat distribution before, during and after the poured shot, pre-heating and solidification of mould, and surface finish texture of the final casting for high pressure die casting process and low pressure die casting process.
This casting simulation software is used for simulating casting in the investment casting simulation, sand casting simulation and die casting simulation.

Altair Inspire Cast

What casting processes does Altair Inspire casting simulation software simulate?

Altair Inspire Cast simulation process is used for following the casting process:

High-pressure die-casting process
Gravity die-casting process
Tilt casting process
Low-pressure die-casting process
Investment casting process

Altair Inspire Cast Software Advantages, Benefits, Applications And Features

Design of casting can be done easily with proper analysis for the riser, runner, gates and mould cavities.
Cracks, flow and defects can be analysed and studied.
Analysis of air trapped air in the small sections of casting,
Helps in deciding the position of the gating system to increase casting yield and reduce the wastage of casting material.
Assist in selecting mould material, design mould, core, core material, vacuum pressure levels and casting defects.
The location of the parting line, vents, riser and entry of the molten metal can be analysed for sound final casting.
Foundry can achieve the best surface finish, dimensional tolerance, shape, counters, quality and accuracy for complex thin wall castings using this simulation software.
Analysis of temperature variation, metal flow, pressure and thermal stresses in the die during the shot, metal flow and solidification process in the die mould.
The computation of this process is faster, calculating the simulation result in less time.
This casting simulation software is used for simulating the investment casting simulation and die casting simulation.

2024 Best Metal Casting Simulation Software List | Mechgrace |