CASTING

Casting Simulation Solutions

ProCAST / QuikCAST

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w w w. e s i - g r o u p . c o m

About ESI Group

Prole
ESI Group has developed an extensive suite of industry oriented applications to realistically simulate a products behavior during testing, to ne-tune manufacturing processes in accordance with desired product performance, and evaluate the environments impact on product performance. With the collaboration of over 600 high-level specialists worldwide, the company and its global network of distributors provided in 2006 direct sales and technical support to customers in more than 30 countries for a global amount of 66.0 M Euros.
PAM-CRASH achieves accurate crash simulation capabilities with enhanced material models such as metals, plastics and composites
Courtesy of Volkswagen AG

Welding simulation of Aluminum automotive construction using SYSWELD simulation solution

Courtesy of IWM

Turnover

International Presence

Headquarters Subsidiaries Offices Agents & Distributors

With twelve field subsidiaries and several distribution agents spanning five continents, ESI Group provides worldwide services and support to its international industrial customers.

Strategy
A development strategy based on the advent of the Digital Factory
The remote digital factory of the future represents a genuine methodological advance. The concept is based on providing all players with a common physical digital prototype, on which they will be able to operate simultaneously. ESI Groups strategy is based on this vision, which assumes that manufacturing industries will inevitably shift toward the all-digital technology. This shift is currently being accelerated by demands of increased competition and spectacular productivity gains that are expected to result. Product Lifecycle Management (PLM) is a crucial part of the digital factory. It is intended to provide computerized monitoring of all activities related to products made by manufacturing companies, including design, production, maintenance and recycling. Paramount to the reliability of virtual simulations is the realistic account of the physics of materials and of the fabricating processes which determine them. This is why virtual manufacturing is the core of any virtual industrial simulation, to predict not only as designed but also as built product performance.

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ESI Group offer is mainly dedicated to 4 major industrial sectors:

SELECTED REFERENCES
Automotive industry:
Allied Signal, Audi, Autoliv, BMW, Breed, Bridgestone, CORUS, Daewoo, Daihatsu, DaimlerChrysler, Delphi, Faurecia, Ford, GM, Honda, Hyundai, Isuzu, Mazda, Mitsubishi, Nissan, Porsche, PSA, Renault, Seat, Shanghai General Motors, Shanghai Volkswagen Automotive, Skoda, Subaru, Takata, Toyota, TRW, Valeo, Visteon, VW, Yamaha,

Automotive industry
Side impact simulation of the new SEAT Len with PAM-CRASH
Courtesy of SEAT

PAM-CRASH provides realistic prediction of occupant behavior in vehicle crashes taking into account seat belts, airbags and car interior paddings
Courtesy of Volkwagen AG

The porosity distribution calculated with ProCAST is taken into account in the crash simulation
Courtesy of BMW and Alcan Technology & Management

Aeronautics/Aerospace industry
Interior acoustic evaluation Noise and vibration predictions

Aeronautics/Aerospace industry:
Airbus Industries, Air Force Research Lab, Bell Helicopter, Boeing, Chengdu Aircraft, EADS, ESA-ESTEC, Harbin Aviation, Howmet, Indian Air Force, Israeli Aircraft Industries, Korea Aerospace Research Institute, Parker Hannifin, Raytheon, Rolls-Royce, Xian Aero Engine,

Helicopter rotor flow-field: one of the most complex fluid flow problems to predict
Courtesy of E-A-R Courtesy of National Research Council of Canada Courtesy of Boeing Company

Heavy industry and Energy

Water fraction analysis in PEM fuel cell Simulation showing the filling of a Harmony sailing boat hull by RTM process with the PAM-RTM software

Heavy industry & Energy:

Air Liquide, Alcan, Alcoa, Alstom, Arcelor, AREVA, BALLARD, Baoshan Iron & Steel, Bombardier, Power System, CEA, EDF, GDF, Hong Fu Jin Precision, John Deere, KOBELCO, LG, Neimeng No.1 Machinery Group, Nippon Steel, ONET, Posco, Serco,

Courtesy of Poncin Yachts Group

Weld repair in nuclear industry

Courtesy of Vitkovize

Electronics & Defense industry:

38th Institute of CECT, DGA, GE, Hitachi, LG Electronics, Lockheed Martin, Martin Baker, NASA, Naval Surface and Undersea Warfare Center, Thales, Tokyo Electron Limited, Toshiba Corp., US Navy, Whirlpool,

Electronics and Defense industry

Model of AIXTRON Planetary Reactor for GaN High Temp MOCVD with 7x2" wafer capacity

Flow and heat transfer analysis of an electrical motor assembly

Parasitic radiation of on-board equipment

Courtesy of Aixtron Courtesy of Alstom Transport

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ESI Group Casting Solutions

ESI Group has developed a set of applications for the foundry industry: QuikCAST, a fast and efficient solution for process evaluation and ProCAST, an advanced tool which is the result of more than 20 years of collaboration with major industrial partners and academic institutions all over the world. QuikCAST focuses on the basics of any casting process: filling, solidification and porosity prediction. ProCAST, based on the Finite Element technology is also able to predict deformations and residual stresses and can address more specific processes like semi-solid modeling, core blowing, centrifugal casting, lost foam and continuous casting. Both software have parallel versions for reducing calculation times.
Stress Solver Gas & Microporosity

Continuous Casting Inverse Primary Phase Flow Solver

Microstructure Grain Structure Hot Tearing Geometry & Meshing

Graphic User Interface (pre & post processors) Material Databases

In the field of modeling of solidification processes, there is much debate between the various numerical techniques used to solve the conservation equations. The arguments are very often based on the numerical technique itself (Finite Differences -FDM-, Finite Volumes -FVM-, Finite Elements -FEM-). There are a few issues that a foundryman or an engineer must know when he wants either to select or use efficiently a simulation software. Just as a seemingly defect free casting from the outside can hide internal microporosity, focusing on pretty pictures can at times lead to false results if the numerical solution is not robust. ProCAST is based on the FEM technique while QuikCAST is based on the FDM technique. Because ESI casting solutions offer both technologies in-house, the customer can be made aware of the advantages and drawbacks of each technique. This provides the major benefit of taking advantage of the speed for setting up the model in QuikCAST to getting the most complete solution with ProCAST. To make this a one step process, ESI is currently working to create a common environment to allow the customer to seamlessly move across both solutions.

Lo Co st foam r eb em low i-s ing olid mod Ce eling ntr ifug al

Thermal Solver

Entry solution For those who require speed above flexibility and expandability FDM Method

When compared with reality (central picture - courtesy of MAN Nutzfahrzeuge, Germany), QuikCAST and ProCAST do produce similar results, in this case isolated liquid pockets in a sand casting. The added advantage that ProCAST provides is towards stress calculations, microstructure results and modeling more exotic casting processes.

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Radiation
ProCAST & QuikCAST ProCAST only

QuikCAST

ProCAST
Flagship casting simulation software Accuracy, flexibility and scalability in one tool Modular solution with advanced features FEM Method

QuikCAST An easy to use and fast solution for evaluating shape casting processes
Originally created by foundry professionals from Aluminum Pechiney in 1985, under the name of SIMULOR, QuikCAST provides a complete industrial solution to foundries and delivers realistic predictions at each step of the casting process. QuikCAST is a user-friendly and industry-specific software package which allows the user to simulate the entire casting process from filling to solidification including defects prediction. It allows for the simulation of complex shapes. Its validated technology is based on powerful solvers with efficient self-correction features* which result in comprehensive realistic results without mesh dependence. QuikCAST has proven to be an indispensable tool in the foundry to validate decisions during prototype conception.

QuikCAST meets industrial needs

Cutting costs and reducing time to market are two of the most pressing problems for the casting industry today. QuikCAST is designed to help the user achieve these goals. It can be used at an early stage for mold and process development and also for cast part quality assessment. QuikCAST solves the full 3D Navier-Stokes equation coupled with the heat conservation equation. Air back pressure, filters, mold roughness, thermal exchanges, die coatings and gravity are accounted for to accurately simulate most casting processes ranging from gravity sand casting to high and low pressure die casting.

Courtesy of Azterlan

Courtesy of Fiat CRF

Courtesy of Interalloy

Courtesy of Teksid

* Technical note
A key factor to obtain accurate results with Finite Difference solvers is the application of local volume and surface correction factors. These correction factors are necessary in order to compute exact volumes but also to apply proper heat transfer and boundary conditions on the external surfaces of the different volumes describing the casting process. QuikCAST includes an efficient algorithm to calculate and automatically apply these surface corrections. One important aspect of solidification modeling is related to the deformation of the solid upon cooling and the build-up of stresses. As it is well known, all the mechanical software available at present on the market are based on unstructured FEM meshes and the reasons is fairly simple to understand. Unlike convection in which the enmeshment is fixed and the velocity of the liquid is described at each nodal point, deformation

coordinate axes, they cannot move. Whereas, with unstructured meshes, the new position of the mesh points can be calculated at each time step, the mesh can be deformed, eventually rebuilt in the case of very large deformations, and the contact/loss of contact events can be detected. Even if numerical tricks are implemented in structured meshes, the problem of stepped interfaces cannot be handled: the basic problem is how to introduce friction or sliding between two stepped surfaces which look like gears. This is why ESI does not (and will never) propose a stress module in QuikCAST: the solution will not be technically sound.

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Qui kCAS T

must be performed on a mesh moving with the solid. This is necessary in particular to handle the loss of contact of two parts of a casting (e.g., the metal and the mould) when an air gap forms or the friction between them when they are in contact. Since structured meshes have to follow

From Quick Model Set up...

Fast automatic mold discretization from the CAD
The entry point of QuikCAST is the input of the mold geometry defined as a set of STL files directly exported from the CAD software. Efficient and automatic tools are available to quickly fix problems related to CAD model quality and to put the components in the right position.

Fast automatic volume blockstructured mesh generation

All separate mold components (core, risers, pouring cups chills) are automatically assembled in the QuikCAST user interface. An automatic volume mesh generator is provided to generate in a few minutes the block-structured mesh used for mold filling and solidification.

Simple and straightforward workflow from

Easy numerical model definition and databases

The input data necessary to define the process is based on exhaustive information yet it is easy to set up. Hydraulic, thermal and contact conditions are defined on surfaces or volumes. Model can be completely remeshed without losing the model set up. Properties and parameters can be retrieved from extensive databases describing: Alloys (aluminum, steel, cast iron, magnesium,...) Mold materials (sand, cores, tool steel, ) Air vents Die coatings

Compelling Benef

QuikCAST offers a complete industria each step of the casting process. QuikCAST is an easy-to-use, fast and Optimize the casting process Study the production feasibility Reduce trial and error Improve yield Improve part quality

to the user and delivers realistic pred

simulation solution, enabling the user

Shorten lead time for mold develop

Investigate new materials and proc

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...to Fast Process Evaluation

All the shape casting processes can be modeled with QuikCAST...
Gravity casting
Most gravity casting processes including sand mold, permanent mold and tilt pouring can be quickly modeled with QuikCAST. Exothermic sleeves, chills and filters (porous or extruded foam filters) are easily and automatically set up according to the process parameters. Thermal Modulus and Hot Spots results can be visualized to validate the size and the position of the risers.
Courtesy of Jihomoravsk Armaturka

Low pressure die casting

QuikCAST has a complete set of dedicated tools for modeling the low pressure die casting process. During the solidification simulation, the evolution of the solid fraction is calculated and used to predict shrinkage locations. Air back pressure calculations together with appropriate user-defined pressure conditions allow for the simulation of vacuum casting processes.

Courtesy of Montupet

High pressure die casting

QuikCAST allows to perfectly simulate the piston displacement during the first phase injection as well as its influence on porosities during the third phase. The definition of the mold cycling sequence, cooling and heating devices are automatically generated through specific menus of the user interface allowing faster pre-processing times. Advanced post-processing features like particle tracing are available to facilitate the visualization of the metal flow.
Courtesy of SAM technologies

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Courtesy of Renault

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Q uikCA ST

QuikCAST has a parallel version based on the SMP technology. Through the years, calculation times for five cycles, filling, solidification and defect prediction were reduced from 37 hours (QuikCAST 2003) to 18 hours (2005) and now down to 5.5 hours (2007) on a 4 processors computer for the part illustrated above in the low pressure die casting paragraph.

I N

Parallel processing

A C TI O N

c predictions at

ProCAST Main Features

ProCAST is a foundry simulation software, which provides coupled thermal-flow-stress analysis based on the finite element method, along with unique metallurgical capabilities, for all casting processes and castable alloys.

ProCAST Solution
Geometry & Meshing Material database Inverse modeling

SOLVERS
Thermal analysis Stress analysis Flow analysis

Grain structure METALLURGICAL Microstructure MODELS Primary phase Gas and micro porosity Hot tearing Lost foam Semi-solid modeling SPECIFIC Centrifugal casting MODELS Radiation Continuous casting Core blowing

From model set-up ...

Part Mold

Geometry & meshing

ProCAST is delivered with a 3D tetrahedral mesh generator and with a CAD reader and analysis tool to facilitate the link between the CAD environment and meshing operations. Available CAD interfaces are: IGES, STEP , VDA, Parasolid, Unisurf, ACIS, UNIGRAPHICS, AutoCAD, CATIA v4 and v5. An automatic shell generator is included to allow the creation of shells for investment casting (including layered shells). It also includes a layered mesh option for increased accuracy and allows the generation of coincident and non-coincident meshes. Surface mesh assemblies and Boolean operations can be performed.

Finite Element Model with cooling channels

Flow solver
The precise geometry description provided by Finite Element models allows ProCAST to predict the metal flow inside the mold and allows for the accurate understanding of:
Sand erosion and turbulences Misruns and cold shuts Air entrapments Overflow positioning

Metal front progression

Fluid flow calculations are described by the full Navier Stokes equation and can be coupled with thermal and stress analysis. Specific models have been added to the flow solver for the analysis of turbulent flows, thixotropic or semi-solid materials, centrifugal castings, lost foam and core blowing.

Thermal solver
Solidification simulation Secondary dendrite arm spacing

The thermal solver allows the computation of heat flow by taking into account conduction, convection and radiation. The heat release associated with phase changes such as solidification and solid phase transformations is described by an enthalpy formulation. Casting issues addressed by the thermal solver include:
Hot spots and porosity Die cooling and heating optimization Macro and micro shrinkage Runner and riser design

Stress solver
The state-of-the-art stress solver enables fully coupled thermal, fluid and stress simulations with elasto-plastic or elasto-viscoplastic material behaviors. Simpler material models such as elastic, vacant or rigid can also be taken into account. Coupled stress calculations can accurately predict:
Thermal and mechanical contact Distortions and deformations Stresses in the casting and die Residual stresses Hot tearing and cracks Fatigue

High fatigue area in the mold

Courtesy of Injecta Druckguss

... to process validation

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Comprehensive material database

An extensive material database is provided with ProCAST. The contents of the material database are continuously expanded with proven properties validated in industry. ProCAST features a unique thermodynamic material database calculator, which allows the user to directly enter the chemical composition of the alloy, and automatically predict temperature dependent properties required to accurately simulate the casting process.
Material database layout and property plots

Continuous casting
ProCAST provides a complete solution for continuous and semi-continuous casting process simulation. The software can simulate steady-state conditions as well as the initial and final stages of continuous casting processes. An application of the MiLE algorithm* applied for Direct Chill casting (DC) of an Al alloy is shown (inlet design, fluid flow, thermal field, effective stress and deformation). An application of a steady-state calculation for a curved continuous casting is also shown. The first picture is colored by the temperature field while the second one shows the fraction of solid field. The Inverse Module enables the automatic calculation of material or process parameters based on measured temperatures at given locations or times. Primary and secondary cooling can be determined by inverse modeling.

Al direct chill casting

User functions
ProCAST also offers a unique capability: the User functions which allow more advanced end users to program their specific process requirements. For example User functions allow to define boundary conditions as time, temperature and space dependent in order to accurately model any specific casting process

Continuous casting of steel

* Technical note
In order to address continuous casting processes, a specific algorithm named MiLE for Mixed Lagrangian Eulerian approach is implemented into ProCAST. The principle of the MiLE algorithm is shortly described here. At the beginning, the casting is divided into two domains 1 and 2. When the continuous casting process starts, the bottom domain (2) moves down. In order to have continuity between domains 1 and 2, new elements have to be introduced between domains 1 and 2 (creating the domain 3). In practice, in order to introduce the new layers of elements, at the beginning of the calculation, a given number of layers of elements of zero thickness are created in between domains 1 and 2. Then, during the casting process, these layers are "unfolded" as an accordion. Domain unfolding during continuous casting process

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ProC AST

MAI N

FEATU R ES

ProCAST Designed By Foundry Experts

High-pressure die casting
The specific needs of high pressure die casting including squeeze casting and semi-solid material processes are covered within ProCAST. Optimal piston velocity profiles, gating designs and overflow positioning can easily be achieved with simulation even for very thin walled structures. Thermo-mechanical calculations can be performed to address not only the issue of die life but also in-service part performance, thus reducing manufacturing risks and costs.

Investment casting, shell casting

ProCAST has dedicated features to address the specific needs of investment casting foundries. For instance, ProCAST can automatically generate a mesh representing the shell mold, allowing for non-uniform thickness to be blended and multiple shell layers created. Also radiation with view factors, including shadowing effects which are critical for high temperature alloys, is taken into account.

Courtesy of Microcast

Courtesy of Toora

Courtesy of ZML Industries

Sand casting
Key success factors in the gravity casting industry focus on optimizing the runner system and on eliminating possible shrinkage areas. ProCAST allows for the simulation of Courtesy of Hitchcock Industries mold filling, solidification and microstructure prediction. The location of risers and the use of insulating or exothermic sleeves and their influence on shrinkage can be studied on the computer and visualized directly on the screen in order to achieve optimal part quality.

Low-pressure die casting

To reproduce industrial production conditions, mold cycles can be performed numerically until the mold has reached steady state temperature conditions. Based on thermal die profiles, mold filling and solidification results, process parameters can be tuned to achieve optimal process quality while reducing time to market.

Courtesy of Rimstock

Courtesy of KWC Engineering

Gravity die casting and tilt pouring

Gravity die casting including tilt pouring processes can be simulated by ProCAST. User can freely define the axis and velocity of rotation.
Gravity die casting
Courtesy of F.O.M.T.

Tilt pouring
Courtesy of Fomet

Courtesy of B&W Diesel

The standard porosity model of ProCAST can take into account not only shrinkage but also expansion during solidification of cast iron. Other factors like the mold rigidity can also be taken into account. A more comprehensive approach to predict porosity in cast iron is also proposed which consists of running coupled thermal, microstructure and porosity calculations. The microstructure solver will compute the evolution of different phases and predict local densities variations. Based on the computed densities, porosity results will be computed.

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...to Solve Foundry Problems

Cold shuts and misruns
Some critical processing conditions, such as cold mold, slow filling, or low casting temperature, can lead to problems during filling. The fully coupled thermal and flow computation enables the designer to assess the temperature drop of the melt during mold filling. Premature solidification adversely influences flow behavior. By capturing these phenomena, ProCAST also predicts when and where incomplete filling or cold shuts may occur. The necessary design changes can be tested and validated, at very low cost, directly on the computer.
Metal front progression around a core

Pipe shrinkage
While solidification seems to proceed smoothly at the surface, large defects may appear inside the castings. For instance, when the risers do not provide sufficient feeding, large shrinkage defects such as piping may occur. With accurate shrinkage defect prediction for all types of alloys, ProCAST allows for rapid modifications and validations of the riser positioning and size.

Pipe Shrinkage prediction for a steel component

Die lifetime, hot tearing and cracks Porosity

Shrinkage porosity is readily addressed by the standard solver. A dedicated module is available in ProCAST to model gas porosity by accurately computing interdendritic shrinkage and taking into account gas content.
Courtesy of Kovolit

ProCAST allows a unique coupling between thermal, flow and stress calculations. The full analysis is performed simultaneously on the same mesh. With ProCAST one can investigate the thermal shock on the tooling during mold filling as well as the influence of gap formation between the casting and the mold during solidification. Hot tears, plastic deformations, residual stresses and distortions are some of the issues which are currently investigated by our industrial customers.
High fatigue areas in the mold

Air entrapment
Air bubbles or oxide layers trapped in areas where fluid flow is restricted may locally weaken the component in service. Turbulence during filling, which may lead to oxide inclusions, is reproduced with ProCAST. The locations of such defects can be easily identified. Since it is possible to directly monitor air inclusions, it can be used to optimize the gating system and the positioning of vents and overflows in high pressure die casting.

Metal (red) and air (blue) visualization in high pressure die casting

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MEETI NG

IN D U ST R I AL

NEED S

Advanced Analysis
Advanced porosity modeling
Developed in collaboration with: Assan, Doncasters, Elkem, EPFL, Hydro Aluminium, Pechiney, Rolls-Royce, Sintef, Snecma and VAW. Most simulation solutions restrict porosity predictions to shrinkage porosity. The software essentially identifies where entrapped liquid is surrounded by solid. This simplified approach does not consider gas porosity. ProCAST is the first commercial software that implements a physicsbased approach for the modeling of shrinkage and gas porosity. It is fully coupled with macro-porosity and pipe shrinkage predictions. The computation of the fluid flow in the mushy zone and the associated pressure drop is based on the Darcy's equation. Additionally, a gas segregation model, along with the proper treatment of solubility limit and pore nucleation is implemented. This comprehensive approach extends the possibilities of foundrymen to explore and understand complex interactions between processing conditions, liquid alloy purity and porosity predictions. No pressure intensification
Effect of piston pressure during the compression stage on the hydrogen porosity in an aluminum high pressure die casting component

Application of pressure intensification

The reduction in gas porosity due to the increased pressure can be identified with the simulation

Yield strength distribution calculation for a ductile iron engine. The mechanical properties are calculated from the microstructure distribution and the thermal history in each zone of the casting

Microstructure modeling & mechanical properties determination

ProCAST includes a microstructure deterministic approach, which enables the prediction of phase formation and transformations, for instance in cast iron and steels. Typical results of a deterministic model include average grain size, dendrite arm spacing, phase fractions, average composition and nodule counts. Mechanical properties, which are of great interest for in service casting performance, can in turn be predicted from microstructure modeling to provide information on yield strength, tensile strength, elongation and hardness. ProCAST also includes more recent Phase Field and PseudoFront Tracking models which provide a direct description of grain morphology evolution and microsegregation patterns in selected zones of the casting.

Pearlite distribution in a sand cast spheroidal iron component

Grain structure modeling

Developed in collaboration with: ABB, AETC, EPFL, Howmet, PCC, Rolls-Royce and Snecma. The grain structure of as-cast components can be an important parameter that the metallurgist has to control. A typical example is the gas turbine blade, which has been solidified under directional heat flow conditions. In this investment casting process, the alloy starts to solidify at the contact with a chill under the form of very fine grains. From this equiaxed zone, the grains which have their crystallographic orientations best aligned with the heat flow direction grow preferentially at the expense of less favorably oriented grains. In the ultimate case, when a single crystal is required for extreme applications, then one grain is selected through a narrow channel under highly controlled solidification conditions. ProCAST computes the grain structure formation during solidification, which is used by many high-end industries to control casting conditions and optimize component performances. ProCAST couples a Cellular Automaton (CA) model with the Finite Element (FE) heat flow computations. For this reason, the grain structure module of ProCAST is often referred to as the CAFE module by industry experts.

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Lost foam
ProCAST includes features that take into account the heat transfer between the liquid metal and the foam, the liquefaction and pyrolysis of the foam pattern, the transport of gas products, the influence of the ceramic coating and the effect of the trapped gas on the movement of the liquid metal.

Core blowing
Developed in collaboration with: Ashland, CTI, CTIF, IMFT, Infun, Laempe, Teksid and Weir Foundries. The European Commission financed during four years a research project aimed at modeling core blowing and gassing. As a result, ProCAST core blowing module accurately predicts blowing and gassing defects, including incomplete fills, low compaction and poorly hardened areas.

Courtesy of Montupet

Details showing unfilled or poorly compacted areas

Courtesy of Infun

Semi-solid modeling
When a semi-solid material is injected in a mold cavity, it's viscosity is depending upon the shear rate as well as the shear rate which was encountered by the metal previously during the injection. When the shear rate is high, the solidifying dendrites are broken and the fluidity is increasing (i.e. the viscosity is decreasing). In order to account for such a behavior, a specific model is included in ProCAST.

Centrifugal casting
ProCAST has the capacity to model centrifugal casting: a shape casting mold is rotated at high speeds about its vertical axis as the metal is poured. The fluid flow equation is solved in a relative (rotating) velocity reference frame.

Courtesy of CSIR

Parallel processing
The ProCAST DMP solution (Distributed Memory Parallel) uses the latest available technology, in particular dynamic domain decomposition and message passing communication. The DMP version includes the main software functionalities to simulate mold filling, solidification with radiation, stress calculations, microstructure computations and is currently available on Linux (32 and 64 bits) and Windows platforms. To reproduce industrial conditions in die casting, thermal cycles are performed to reach steady state temperatures. While a traditional 1 processor configuration allows the user to simulate 4 complete die cycles in two and half hours, a more powerful configuration with up to 16 processors and Infiniband interconnect will give the same result in 18 minutes!

Courtesy of Rimstock

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AD VANCED

ANALY SI S

Streamlined and Productive Environment

Key features
Visual Environment
Windows look and feel intuitive interface Multi-model, multi-page, multi-plot environment Model manipulation tools Interactive slicing, scanning and Xray viewing modes Contour, cut off and vector display of simulation results Results animations Particle tracing Curve plotting functionalities Flexible switching between pre-post processing solutions Results and geometry export functionalities Image and movie output for reporting and communication Automatic report generation in PDF and Powerpoint format Support of session files (scripts)
Courtesy of CMS Jant

Visual environment
ProCAST offers a post-processing tool fully integrated in the open collaborative engineering environment of ESI Group. This environment is an integrated suite of solutions providing within a single environment an access to multiple applications in different simulation disciplines. ProCAST and QuikCAST, and also the appropriate geometrical tools, will therefore be part of this single unified environment allowing interoperability and chaining between both casting software and other disciplines of simulation. VisualCAST (post-processing) is the first application derived from Visual-Viewer, the new state-of-the-art plotting and animation solution of ESI Group.

Visual process
Visual Process
Process guidance approach which helps the user to build simulation model step by step from start to finish Standardization of corporate modeling Capturing best practices Automation of repetitive model building Shorten the investigation of various scenarios Fully automatic model creation and report generation Reduction of human errors occurrence in routine simulation tasks Reliable and consistent modeling
Courtesy of Ashland & Betsaide & Inasmet

Preparing a simulation model for process evaluation is often a time consuming task. Using VisualPROCESS, an advanced CAE environment for process customization and automation, engineers gain productivity and save time on modeling. VisualPROCESS simplifies and automates repetitive tasks by process guidance approach. The process templates customize any procedure and capture corporate best practices.

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Consulting Services, Training and Support

Consulting Services
R&D Projects with both academic and industrial partners aiming to enhance industrial applications on the basis of university research Methodology Projects in order to validate specific simulation methodologies by transferring know-how to the industry Production Projects carrying out dedicated simulation tasks On-Demand Projects for immediate availability for fast problem solving

Customer Statements
With ProCAST we got an efficient tool for checking and optimizing what our mold designers could only assume in the past. With our first simulation we were able to correct successfully the gating system of a problematic HPDC tool for an aluminum casting in an impressive way. Jrg Lagemann, Engineering Manager, Alu Menziken Injecta Druckguss AG, Switzerland For several years, ProCAST has been used at Howmet for customer concurrent engineering, development of new components and optimization of our investment casting processes. ProCAST allows us to quickly optimize our gating systems in terms of filling and solidification. Simulation results are then stored in a technical database used by our product and process development department. Loc Calba, CAD & Process Modeling Manager, Howmet S.A.S., France The simulation calculations carried out with ProCAST in sand casting were an extremely valuable help in order to obtain a low-cost and fault free first cast of cylinder crankcases in spheroidal iron. Thomas Schuszter, Manager Process Engineering and Pattern Shop, MAN B&W Diesel AG, Germany ProCAST is an extraordinary software when it comes to complex thin walled components. Stefan Gustafsson Ledell, Technical Coordinator Casting Design, Swedish Foundry Association, Sweden To estimate the interfacial heat transfer coefficients, we conducted low pressure die casting and squeeze casting experiments. The measured cooling curves from thermocouple locations in the die and cavity agreed well with the ProCAST results. Bob Pehlke, Professor, Dept of Materials Science & Engineering, University of Michigan, USA All new castings are simulated with ProCAST before the first trials. The number of faulty castings was reduced since then. Stefan Nelle, Research and Development Engineer, Walzengiesserei Coswig GmbH, Germany ProCAST has been implemented in our company for a number of years. Its usage has demonstrated to be valuable in the design of dies for our low pressure die casting machines. Michael Bader, Technical Manager, KWC AG Engineering, Switzerland We produce safety components for the automotive industry. It is therefore essential for us to guarantee metallurgical quality for all manufactured components while reducing development times. Since 1995, ProCAST has helped us meet these industrial requirements Marcello Boschini, Brembo, Italy

Training Services
ESI Group training courses are provided by highly skilled engineers responsible for consulting and support activities, with years of practice and field experience. Training services are delivered to our customers using all modern techniques, either via standard training sessions as defined in our course catalogue or via customized training that answers to specific needs, including long-term training for rosters of new hires. The courses address software usage and extend to industrial problem-solving.

Support Services
From worldwide on-site contracting to technical assistance and our daily hotline, ESI Group's engineers help you achieve better and faster results in casting simulation.

ProCAST receives Frost & Sullivan award

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ESI Group around the world

ESI GROUP HEADQUARTERS ESI Group
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EUROPE
F R A NCE
ESI FRANCE Sales & Technical Headquarters PARC D'AFFAIRES SILIC 99 RUE DES SOLETS BP 80112 94513 RUNGIS CEDEX France Phone: +33 (0)1 49 78 28 00 Fax: +33 (0)1 46 87 72 02 ESI FRANCE LE RCAMIER 70 RUE ROBERT 69458 LYON CEDEX 06 FRANCE Phone: +33 (0)4 78 14 12 00 Fax: +33 (0)4 78 14 12 01

ASIA
BE NE LUX & S C ANDIN AV I A
ESI BV Radex Innovation Centre Room 4.57 Rotterdamseweg 183 C 2629 HD Delft The Netherlands Phone: +31 (0)15 2682501 Fax: +31 (0)15 2682514

J A PA N
Nihon ESI K.K. Headquarters & Sales Division Yoyogi-Uehara West Bldg, 45-18 Oyama-cho - Shibuya-ku Tokyo 151-0065 Japan Phone: +81 3 6407 2347 Fax: +81 3 6407 2395 Nihon ESI K.K. Kansai Branch Office Advance Esaka 5F, 8-10 Toyotsu-cho - Suita-shi, Osaka 564-0051 Japan Phone: +81 6 6330 2720 Fax: +81 6 6330 2740 Nihon ESI K.K. Technical Office Yoyogi-Uehara West Bldg, 45-18 Oyama-cho - Shibuya-ku Tokyo 151-0065 Japan Phone: +81 3 3466 6866 Fax: +81 3 3466 6863

C HI NA
ZHONG GUO ESI CO., LTD Unit 608A, Guangdong Soft-Park No. 11 Caipin Road, Complex bldg Guangzhou Science City (GSC) Guangzhou city 510663 China Phone: +86 (020) 3206 8272 Fax: +86 (020) 3206 8107 ATE Technology International LTD Room 16A, Base F Fu Hua Mansion No. 8 Chaoyangmen North Avenue Beijing 100027 China Phone: +86 (10) 6554 4907 Fax: +86 (10) 6554 4911

CZ E C H R E P UB LIC
& EASTERN EUROPEAN COUNTRIES

G E R MANY
ESI GmbH Sales & Technical Headquarters Mergenthalerallee 15-21 D-65760 Eschborn Germany Phone: +49(0)6196 9583-0 Fax: +49(0)6196 9583-111 ESI GmbH Niederlassung Mnchen Augustin-Rsch-Str. 23 80935 Mnchen Germany Phone: +49 89 43 650017 Fax: +49 89 43 650019

MECAS ESI s.r.o. Brojova 2113/16 326 00 Pilzen Czech Republic Phone: +420 377 432 931 Fax: +420 377 432 930

I ND I A
Sales & Technical Branch Office Indrakrupa #17, 100 feet ring road 3rd phase, 6th block, Banashankari 3rd stage Bangalore 560 085 India Phone: +91 98809 26926 Fax: +91 80401 74705

SPA IN
The Virtual Try-Out Space S.L. Edificio IKEA, Oficina 311 C/ Estartetxe, 5 48940 Leioa (Bizkaia) Spain Phone: +34 94 480 47 60 Fax: +34 94 480 51 99

AGENT:

KOR E A
Hankook ESI 157-033, 5F KOMEGA bldg., 660-6 Deungchon-3Dong, Gangseo-ku Seoul South Korea Phone: +82 2 3664 0073 Fax: +82 2 3662 0084

UNITE D K ING D OM
ESI-UK Limited John Eccles House Robert Robinson Avenue The Oxford Science Park Oxford, OX4 4GP United Kingdom Phone: +44 (0) 1865 338007 Fax: +44 (0) 1865 338100

S W ITZ E R L AND
Calcom ESI SA PSE-A CH-1015 Lausanne Switzerland Phone: +41 21 693 2918 Fax: +41 21 693 4740

S OU TH- EA S T AS I A
ESI Group South-East Asia Technical Office 96-1, Jalan PJU 1/3B SunwayMas Commercial Center 47301 Petaling Jaya, Selangor Malaysia Phone: +60 (3) 78049973 Fax: +60 (12) 2739978

AMERICAS
U SA
ESI North America Corporate Headquarters 12555 High Bluff Drive Suite 250 San Diego, CA 92130 USA Phone: +1 (858) 350 0057 Fax: +1 (858) 350 8328 ESI North America Commercial Headquarters 36800 Woodward Avenue Suite 200 Bloomfield Hills, MI 48304 USA Phone: +1 (248) 203 0642 Fax: +1 (248) 203 0696 ESI US R&D 6767 Old Madison Pike Suite 600 Huntsville, AL 35806 USA Phone: (256) 713-4700 Fax: (256) 713-4799

S OUT H A ME R IC A
ESI Group South America Technical Support Office Rua Artur de Azevedo, 1857 cj.45 So Paulo - SP 05404-015 Brazil Phone/Fax: +55 11 3062-3698

Selected Casting References

ABILITY - ACTECH - AIDC - AKKA - ALCAN NEUHAUSEN - ALCOA WHEEL PRODUCTS - ALFA MICROFUSION - ALUMINIUM LEND - ALUPRESS - ALUTEC - AMTEK - ANJI FOUNDRY WORKS - ARCS AUSTRIAN RESEARCH CENTER - ARPEK - ASM ASSEMBLY AUTOMATION AWE ALDERMASTON - AZTERLAN - BASSANO GRIMECA - BEIJING AERO. MATERIAL INSTITUTE - BLACK & DECKER - BHLER EDELSTAHL - BOSCH CHASSIS SYSTEMS INDIA - BP SOLAR - BREMBO - CAR IMAGE - CARPENTER TECHNOLOGY - CEA VALDUC - CENTRO SVILUPPO MATERIALI - CHINA NATIONAL SOUTH AERO. - CITATION - CMS JANT VE MAKINA SANAYII - CNRC-ICI - COMPONENTES VILLANOVA - CONSOLIDATED METCO - CORUS TECHNOLOGY - COSTAMP - COSWIG - CSIRO AUSTRALIA - CTIF - CUSTOMER - DAIMLER CHYSLER - DAISIN - DALIAN HEAVY INDUSTRIES STEEL CASTING - DANA DIVISN SH - DAYOUM-TECH (DURAE METAL) - DENSO - DGP HINODAY INDUSTRIES - DLR - DSB EURO - EMERSON MOTOR TECHNOLOGIES - ENKEI - ESCO TURBINE TECHNOLOGY - FAB (FONDERIE ET ATELIER DU BELIER) - FAGOR EDERLAN - FALCON FOUNDRY COMPANY - FLORENCE ET PEILLON - FOMA - FOMET - FONDERIA OFFICINE MECCANICHE TACCONI - FONDERIA SCACCHETTI LEGHE LEGGERE - FONDERIE DE TAMARIS - FONDERIEBREA - FORD CORP . - FSUE MMPP SALUT - FUNCASA - FUND. ESTANDA - GAMCO COMPONENTS GROUP - GE ENERGY - INDIA - GE R&D - GENERAL ALUMINUM - GENERAL MOTORS R&D - GEORG FISCHER MSSNER - GHIAL - GSC FOUNDRY CORP GUANGDONG HONGTU TECHNOLOGY - GUANGZHOU SEAGULL - HARBIN DONGAN ENGINE - HINDUSTAN AERONAUTICS - HITACHI PLANT TECNOLOGIES - HITCHCOCK INDUSTRIES - HONDA ENG. - HONG FU JIN PRECISION INDUSTRY - HOWMET(ALCOA HOWMET CASTINGS) - HUTA MALAPANEW OZIMEK - HYDRO ALUMINIUM (VAW) - HYUNDAI HEAVY IND. - IAV - INASMET - INDO SHELL CAST PVT - INDUGA KWC - INDUSTRIE METALLURGICHE SPOLETO - INOSSMAN FONDERIE ACCIAIO - INTERMET (TOOL PRODUCTS) - INTI MECNICA - INYECTAMETAL - ITT IND./GOULD PUMPS - JIANGLU GROUP - JIHOMORAVSK ARMATURKA - KAWASAKI HEAVY INDUSTRIES - KEMPER - KIMM - KITECH - KOVOLIS HEDVIKOV - KURTZ - LECLAIRE MANUFACTURING - LESUEUR - LOSTWAX - MAHLE TECHNOLOGY - MAN B & W DIESEL - MANOIR INDUSTRIES PITRES - MATTEK CSIR - MAZDA MOTOR CORP - MFL - MICHELIN - MICROFUSIONE STELLITE - MICROSTEEL - MITSUBISHI - MONTUPET NOGENT S/OISE - NAMTEC - NEIMENG NO. 1 MACHINERY GROUP - NEPTUNO - NETSUREN - NEUE MATERIALIEN FRTH - NIFFT - NIPPON LIGHT METAL COMPANY - NISSAN INDUSTRY - NORFOLK NAVAL SHIPYARD DETACHMENT - NOVELIS SWITZERLAND - ODLEWNIE POLSKIE - PACIFIC CAST TECHNOLOGIES - PBS VELKA BITES - PCC AIRFOILS - PCC STRUCTURALS - PEEKAY STEEL CASTINGS - PERM MOTORS GROUP - PRATHISTAN ALLOY CASTINGS - PRATT & WHITNEY - PRECICAST BILBAO - PSA BELCHAMP - QINGAN GROUP - REINER BRACH - RENAULT RUEIL - ROLLS ROYCE SALZGITTER MANNESMANN FORSCHUNG - SAM TECHNOLOGIES - SAMJEONG TURBINE - SAMKEE MACHINERY - SANDIA NATIONAL LABORATORIES - SECAT - SETVAL CEV VALLOUREC - SFU (FONDERIE USSEL) - SHANGHAI HONGGANG - SHANXI VEHICLE ENGINE INSTITUTE - SHENG TAI BRASSWARE - SHENYANG HEAVY MACHINERY GROUP - SHENYANG LIMING AERO-ENGINE GROUP - SIEMPELKAMP - SILICON MEADOWS DESIGN - SMS DEMAG - SNECMA MOTEURS - SPARTAN LIGHT METAL - ST. CLAIR DIE CASTING STRYKER HOWMEDICA OSTEONICS - TANAKA SEIMITSU - TEXMO PRECISION CASTINGS - UMICORE BELGIUM - UTTAR PRADESH STEELS - VIKRAM SARABHAI SPACE CENTER - VILLARES METALS - VSB TU OSTRAVA - VULCAN SFM - WELLS MANUFACTURING COMPANY (DURABAR) - WIELAND WERKE - WRIGHT PATTERSON AFB-OHIO - WSK RZESZOW - WUXI YINPU - XI'AN AERO ENGINE COMPANY - YAMAHA MOTOR - YUANQING ALUMINIUM WHEEL - ZHUHAI HUARUN WEISIDA ELECTRONIC INSTITUTE - ZIMMER

Copyright ESI Group 2007 - PAM-SYSTEM and all PAM-product names are trademarks of ESI Group - All other trademarks are the property of their respective owners. Specifications are subject to change without notice. Cover pictures courtesy of Hitchcock Industries, Inossman Fonderie Acciaio, Kovolis Hedvikov, MAN B&W Diesel, Ronal, Stryker Howmedica, Tecnalia-Fundicin.

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