ProCast

The industry-leading manufacturers have relied on casting simulation software, ProCAST, for decades to produce defect-free parts at a competitive rate. ProCAST helps to predict, analyse, measure and quantity casting defects in the early design stages by simulating the entire process – from furnace to final casting.

Casting Simulation Software

Simulation allows cast parts manufacturers to test their casting processes fully and virtually and to enable this early in the process development cycle. Accurate defect prediction and quantification and the right process design are imperative to ‘get it right’ during production trials.

With ESI’s proven casting simulation software ProCAST, you can cast your parts right the first time, every time – meeting your deadlines and never wasting money on scrap parts or late redesigns. ProCAST comprehensively addresses most castable alloys and casting processes such as sand casting, die casting, investment casting, and their multiple process variants. For decades, customers have relied upon ProCAST as their go-to tool for the casting process essentials – filling, solidification, and porosity prediction.

Boasting advanced physics and Finite Element technology, it also predicts complex phenomenon, tracking residual stresses through the process and predicting subsequent deformations leading to dimensional variations and lower die/tool life, as well as compute microstructure, grain structure & mechanical properties, which are much needed for the components to have an increased lifetime.

Highlights of Casting Simulation with ProCAST

MAIN ProCAST USER BENEFITS

Work hand-in-hand with customers providing part design to check for castability issues as early as possible in the process, to accelerate the start of production
Deliver accurate quotes, with precise material cost estimates to safeguard your margins
Predict, analyze & quantify the most common casting defects and design process in advance to reduce your scrap rates and expensive reworks, hence securing delivery & quality commitments
Improve parts quality to gain new customers

MAIN ProCAST APPLICATIONS & PREDICTED DEFECTS

Comprehensive Porosity Models for piping, shrinkage, micro & gas porosity covering various alloys and process
Address various filling-related defects (air entrainment, oxides, surface defects, cold shuts, misrun, ...)
Track residual stresses and control distortion
Predict microstructure evolution & improve mechanical properties
Design process to achieve desired grain structure
Determine the right production process window and optimize the process
Address various other casting processes including Centrifugal, Continuous Casting, DC Casting, Lost Foam, Semi-Solid, ...
And adjacent processes like Core Blowing, Core Gassing/Drying, Heat Treatment

Casting Simulation Webcast Now Available On-Demand

Interested in hearing how ProCAST is essential to ensure getting casting parts right the first time, meeting deadlines and cutting costs on scrap parts or late redesigns? With its finite element technology, you can predict complex issues like deformations and residual stresses and comprehensively address most castable alloys and most casting processes like sand castings, die castings, investment castings and multiple variants associated with these processes.

During an exclusive digital digital event, casting engineers from Kovolis Hedvikov, MCS and Azterlan shared how they predict, analyze, measure and avoid casting defects in the earliest stages of design.

WATCH ON DEMAND

ProCAST helps engineers and manufacturers to meet all quality requirements and produce first-time-right parts by proving insights into the following:

• Residual stresses & distortions
• Microstructure & heat treatment
• Advanced porosity model
• Grain structures
• Process optimization

Sand casting foundries

Optimize the gating system & eliminate the risk of shrinkage porosity

Model any sand-casting process, including high-pressure molding lines. Study filling, soldification & residual stresses as well as the effects of feeder locations, filters, chills, insulation & exothermic sleeves on the casting process and quality.

Die casting

Reproduce shop floor conditions

Use casting simulation to perform several production cycles and obtain steady-state die temperatures. Study filling, solidification, intensification pressure effect, cooling design & process parameters optimization.

Investment casting

Efficiently control the entire process to cast intictate designs

Automatically generate the mesh representing the shell mold. Allow blending for non-uniform shell thickness and creation of multiple shell layers. Consider radiation with view factors, including shadowing effects critical for high-temperature alloys.