FAQ's

  • Can we predict shrinkage porosity using casting simulation?
  • o Yes. casting simulation software such as ADSTEFAN can be used for casting defects analysis such as shrinkage porosity prediction by simulating the metal casting process. Considering all variables in metal casting process such as material properties, cooling rates, and mold & methoding design and by analyzing these variables, the casting simulation software can forecast areas prone to shrinkage porosity and help in Gating optimization to minimize shrinkage porosity.
  • Can we predict misrun casting defect using casting defect simulation software?
  • Yes, using casting defect simulation software like ADSTEFAN we can predict misrun defects by simulating the casting melt flow simulation. Engineer can simulate solidification stages of the casting process, identifying areas were inadequate metal flow results in incomplete casting formation.
  • How to predict Cold shut casting defect using casting process simulation software?
  • o Cold Shut defect in metal casting occurs due to inadequate metal flow leading to incomplete fusion between two advancing fronts. Casting simulation software such as ADSTEFAN shows the temperatures at the two moving metal fronts in a dynamic and continuous manner. If the temperature of the flow fronts drops less than solidus temperature, there is a potential of formation of cold shut casting defect.
  • Which industries benefit from casting simulation?
  • Industries such as automotive, aerospace, construction, and any sector that requires high-quality metal components benefit from casting simulation. It is particularly valuable in sectors where precision and reliability are critical.
  • Can we predict hot tear casting defect using casting defect simulation software?
  • o Yes, We can predict hot tear casting defect using casting simulation software such as ADSTEFAN. Hot tear in casting occurs due to rapid cooling rate during solidification of casting. Using casting simulation software we can understand local casting cooling rates and generation of cooling rate graphs we can identify potential areas of hot tear casting defects.
  • Can we predict crack type casting defect using casting defect simulation software?
  • Yes. Cracks (or fractures) formed in metal casting can be predicted using casting defect simulation software. Non-uniform cooling of a casting results in difference in temperature gradients in the casting and causes thermos elastic stress which leads to crack casting defect. This phenomenon can be predicted by casting simulation software such as ADSTEFAN.
  • Can we predict warpage casting defect using casting simulation software?
  • Yes. Warpage defect in metal casting can be predicted using casting simulation software. Warpage is distortion in cast part where after solidification there will be change in intended shape/ dimensions. Uneven cooling leads to residual stresses and dimensional distortions in castings. Engineers can predict warpage and distortion casting defect using casting simulation software such as ADSTEFAN.
  • Can we predict Blowholes casting defect using casting simulation software?
  • Yes. By using casting simulation software can predict blowholes casting defect. Blowholes in casting are formed due to air pocket isolation during filling of molten metal inside mold casting. Using casting simulation software, we can simulate mold filling pattern and can predict air pocket isolations . By this engineer can identify areas where trapped gases are present, that results in gas porosity or blow hole casting defects.
  • Can we predict Sand inclusion casting defect using casting simulation software?
  • Yes. Sand inclusion type of sand casting defects can be predicted using casting simulation software like ADSTEFAN. Sand inclusion defect caused due to high velocity and turbulence created during the melt flow in the mold . Melt velocities in of mold, and turbulence can be simulated using casting simulation software. Engineers predict and modify the mold design and gating to reduce the melt velocities and avoid turbulent filling to avoid casting defect such as sand inclusion casting defect in casting.
  • Can we use for HPDC simulation software for gating optimization?
  • Yes, by using ADSTEFAN software for gating optimization. Engineers can optimize gating in high pressure die casting simulation by analyzing behavior of metal flow, velocity, pressure distribution and solidification pattern for given design thus by checking all methoding design and process parameters efficiency. Best design and parameter option are selected for high casting quality, yield and process ease of making.
  • Can we use casting simulation for LPDC gating optimization & Process optimization?
  • Yes, we can simulate metal flow analysis and solidification virtually, and root cause assessment using LPDC simulation. we can enhance casting quality and minimize casting defects through ADSTEFAN Casting simulation software for Low pressure die casting gating optimization and process optimization.
  • Can we use GDC simulation software for gating optimization
  • Yes, gravity die casting simulation software such as ADSTEFAN will help to determine best gating design and process parameters by analyzing metal flow dynamics and solidification behavior of casting inside die cavity, aiding in the design of efficient gating systems to improve casting quality and minimize casting defects.
  • Can we use sand casting simulation software for gating optimization
  • Through sand casting simulation software such as ADSTEFAN we can optimize gating design by understanding behavior of molten metal flow inside cavity and solidification pattern achieved inside sand mold and predict probable casting defects and root causes. By validating different gating concepts user can assess best gating considering feasibility, quality and yield factors.
  • Can we use Shell molding simulation software for gating optimization
  • Through ADSTEFAN casting simulation software we can simulate shell molding simulation process to understand behavior of molten metal flow, solidification pattern within shell for different gating design and choose best gating considering feasibility, quality and yield factors.
  • Can we use investment casting simulation for gating optimization
  • Using ADSTEFAN casting simulation software, we can conduct the investment casting simulation process. By studying behavior of molten metal flow and solidification patterns inside investment shell mold and across various gating designs, enabling the selection of the optimal gating configuration based on factors like feasibility, quality, and yield. Using such methodology engineer can do gating optimization of investment casting.
  • Why is casting simulation software used?
  • Casting simulation software is used to predict defects in the casting process by simulating fluid flow, heat transfer, and solidification behavior. It helps identify defects, casting gating optimisation, and enhance efficiency, ultimately reducing costs and minimizing production risks
  • What is the purpose of casting mold flow simulation?
  • Casting mold flow simulation software serves to casting defect simulation and optimize manufacturing processes by simulating fluid flow, heat transfer, and solidification behavior. Its purpose is to identify potential defects, gating optimization and process parameters, and enhance efficiency of production, thereby reducing lead time, costs and risks.
  • How Casting simulation benefits foundries?
  • o Casting simulation aids foundries by gating optimization and processes optimization , reducing defects and scrap, and helping in casting rejection reduction, casting yield increase, and helping in productivity enhancement. Casting simulation also allows for virtual testing and validation, saving time and resources in physical trials.
  • Is casting simulation software accurate?
  • o Casting simulation software provides reliable predictions of casting processes, but accuracy depends on input data quality and the complexity of the model and accuracy range with quality data inputs we can achieve 85 – 90 % accuracy.
  • Which is the best casting simulation software?
  • Determining the best casting simulation software depends on your specific needs, budget, and industry. As per recent surveys conducted ADSTEFAN casting simulation software is deemed as the best casting simulation software with USP as per foundry needs and offers innovating features, friendly GUI with affordable cost.
  • Is ADSTEFAN casting simulation software accurate?
  • ADSTEFAN casting simulation software provides reliable predictions of casting processes, using advanced algorithms to simulate filling, solidification, and cooling stages accurately. This has been demonstrated by benchmarking exercise done by several 100s of customers all over world, including in India. Accuracy and speed are achieved due to proprietary algorithms developed by research at Hitachi, Japan.
  • Can we use casting simulation to predict Casting defects and remedies?
  • Casting defects and remedies can be simulated virtually by using Casting Simulation software technology. We can visualize how molten metal is filling mold and casting solidification simulation. From these we can perform air entrapment simulation, shrinkage porosity prediction, Thermal balancing die casting and understand root cause of casting defect in broader way
  • What benefits do we get using aluminium die casting simulation software?
  • We can perform casting methods simulation for existing methoding design and gating optimization along with process parameters optimization can be performed to achieve defect free casting in first trial itself using aluminium die casting simulation software
  • What benefits do we get using casting method design software?
  • Casting method design software such as ADSTEFAN offers precise simulation capabilities, ensuring gating optimization and process parameters optimization. It facilitates rapid prototyping and iteration, reducing lead product development time. Additionally, it enhances efficiency by minimizing material waste and energy cost saving.
  • Is metal casting simulation software user-friendly?
  • Yes, modern metal casting simulation software such as ADSTEFAN casting simulation software often offers user friendly GUI and comprehensive tutorials to assist users in utilizing its capabilities effectively.
  • What are inputs for Sand casting simulation?
  • Inputs required for Sand casting simulation software are:
    1.3D CAD - Casting, Gating, Mold (Optional), Core, Chills, Sleeves, filters in .stl format
    2.Process parameters – Casting material grade, Mold grade, Pouring rate, Metal pouring temperature, Mold temperature.
  • What are inputs for high pressure die casting simulation software?
  • Inputs required for high pressure die casting simulation software are:
    1.3D CAD - Casting, Gating, Die(Optional), Cooling lines, Core, Inserts if considered in process
    2.Process parameters – Casting material grade, Die grade, First phase and second phase velocity and switch position, Metal pouring temperature, Die temperature.
  • What are inputs for LPDC simulation ?
  • Inputs required for LPDC simulation are:
    1.3D CAD - Casting, Gating, Die(Optional), Cooling lines, Core, Chills, Sleeves , filters in .stl format
    2. Process parameters – Casting material grade, Die grade, Pressure Vs Time graph, Metal pouring temperature, Die temperature.
  • What are inputs for gravity die casting simulation?
  • Inputs required for gravity die casting simulation are:
    1. 3D CAD - Casting, Gating, Die(Optional), Cooling lines, Core, Chills, Sleeves , filters in .stl format 2. Process parameters – Casting material grade, Die grade, Pouring rate, Metal pouring temperature, Die temperature.
  • What are inputs for tilt gravity die casting simulation?
  • Inputs required for tilt gravity die casting simulation are:
    1. 3D CAD - Casting, Gating, Die(Optional), Cooling lines, Core, Chills, Sleeves , filters in .stl format 2. Process parameters – Casting material grade, Die grade, Pouring rate, Tilt condition, Metal pouring temperature, Die temperature.
  • What are inputs for Shell molding simulation?
  • Inputs required for Shell molding simulation are:
    1. 3D CAD - Casting, Gating, Mold (Optional), Core, Chills, Sleeves, filters in .stl format
    2. Process parameters – Casting material grade, Shell grade, pouring rate, Metal pouring temperature, Shell temperature.
  • What are inputs for investment casting simulation software?
  • Inputs required for investment casting simulation software are:
    1. 3D CAD - Casting, Gating, Mold (Optional), Core, Sleeves, filters in .stl format
    2. Process parameters – Casting material grade, Shell grade, pouring rate, Metal pouring temperature, Shell temperature.
  • How to reduce casting defects ?
  • o Identification of casting defect root cause is critical as gating optimization and process optimization is performed based on root cause of casting defects. With help of casting simulation software, we can easily identify root cause so necessary corrective actions can be taken up and optimize process and design well before shop floor trials.
  • How to overcome Gas porosity/Blow holes casting defects
  • 1 Ensure proper mold venting and gating design to facilitate gas escape.
    2 Control pouring temperature and rate to minimize gas entrapment.
    3 Implement degassing techniques like vacuum or inert gas processes to remove dissolved gases from the molten metal.
    4 Use air entrapment prediction tools such as casting simulation to virtually visualize cavity filling and provide vents at air entrapped locations.
  • How to overcome shrinkage porosity casting defects
  • 1. Implement proper gating and risering designs to ensure adequate feeding of molten metal during solidification.
    2. Modify casting parameters such as cooling rate and pouring temperature to minimize shrinkage.
    3 Use shrinkage porosity prediction tools such as casting simulation to virtually visualize solidification pattern of metal and check for potential hotspot in casting.