Casting simulation
Introduction.1
Casting process simulation uses computer programs to help us
understand what happens during casting. It shows how the metal fills the
mold, cools down, and becomes solid. The simulation also helps us predict
the quality of the casting, such as its strength, shape changes, and
.possible problems like cracks
Before we start real production, the simulation can show us what the final
casting will look like. This helps engineers design the best way to pour and
cool the metal. It also saves time, materials, and energy because we don’t
.need to do many test castings
Casting simulation programs are very useful. They can show problems like
shrinkage, sand getting into the metal, or cold shuts. These programs also
help in designing the part, choosing the right way to melt the metal, and
planning steps like mold making and heat treatment. This reduces costs
.during the whole casting process
Simulation means using math and computers to copy real-life casting
processes. Engineers can use these tools to fix problems with current
.castings or create new designs without needing real tests
This technology started in the 1970s in universities, mostly in Europe and
the U.S. Since the 1980s, many companies have created casting
simulation software. It is now one of the biggest improvements in casting
in the last 50 years. It helps engineers see what happens inside the mold
.and improve the final product
: Steps using Pro Cast.2
Improt 3D CAD Model (Parasolid , IGES , STEP ,STL ) .1
Surface check & Repairing .2
Processing in 2D Mesh & 3D mesh.3
Processing Cast .4
Processing in viewer ( simulation) .5
Surface check & Repairing
The main goal of the repair process is to create a complete, enclosed
volume or a smoothly connected surface model. Common topological
issues that often arise from CAD modeling or file conversion include
overlaps, T-junctions, surface intersections, and open areas (caps or
.cavities)
To address these issues, the Repair dialog box provides tools that can fix
them in different ways: automatically, semi-automatically, or through
manual adjustments using repair , Assembly or intersection options
2D & 3D Mesh Generation
Mesh generation is one of the most critical steps in any
casting simulation, as it defines how accurately the
geometry and physical phenomena will be represented
during analysis. In ProCAST, both 2D and 3D meshing
are used depending on the complexity and
.requirements of the component
Objective of Meshing
The purpose of meshing is to divide the geometry into
small finite elements where mathematical calculations
can be performed. A well-constructed mesh ensures
high accuracy in simulation results, particularly in
regions with complex geometry or high thermal and
.mechanical gradients
2D Mesh
The 2D mesh is generated first as a surface
.representation of the geometry
This step ensures that all surfaces are correctly
.defined and connected
During this phase, attention is given to mesh quality,
.avoiding distorted or highly skewed elements
Mesh size and element type (triangular or
quadrilateral) are selected based on the level of
.detail required
Surface mesh is checked for continuity, gaps, and
overlaps to ensure a smooth transition to 3D
.meshing
3D Mesh
After completing the 2D surface mesh, it is extruded
.or filled to create a volumetric 3D mesh
The 3D mesh represents the entire volume of the
.part and the surrounding mold
Proper refinement is applied to critical areas such as
thin walls, ingates, risers, and expected defect zones
.to capture accurate behavior
Hexahedral, tetrahedral, or hybrid mesh types may
be used based on the geometry and solver
.requirements
Mesh Quality and Validation
The mesh is validated to ensure there are no errors
such as intersections, free edges, or non-manifold
.connections
Element size and distribution are optimized to
.balance simulation accuracy with computation time
Special mesh controls are applied in regions where
thermal or flow gradients are expected to be
high,such as gates or corners
Importance in Simulation
A high-quality mesh is essential for achieving reliable
simulation results. It directly affects the accuracy of
:predictions related to
Mold filling behavior
Solidification patterns
Temperature distribution
Shrinkage and porosity formation
Stress and deformation during cooling
By carefully generating and validating both 2D and 3D
meshes, the foundation is laid for accurate and efficient
.casting process simulation in ProCAST
2D MESH
3D MESH
Processing Cast
After meshing, the next essential step in ProCAST is
defining the casting part itself, commonly referred to
as the Cast. This step involves assigning the role and
material of the component that will be filled with
.molten metal during the simulation
Purpose of the Cast Step
:The objective of the Cast step is to
Identify the part of the geometry that represents the
.actual casting component
.Assign the appropriate alloy or metal to this part
Define the initial conditions for the metal during mold
.filling and solidification
Steps Performed
Selection of the Casting Part
The meshed component (e.g., a rim, bracket, or
.housing) is selected and designated as the Cast
This separates it from other parts of the system
.such as molds, cores, chills, or feeders
Material Assignment
A specific alloy or material is selected from the
.ProCAST material database
In this project, [insert your alloy name, e.g.,
A365 Aluminum Alloy] was chosen due to its
.suitable mechanical and thermal properties
The database provides material properties such
:as
Liquidus and solidus temperatures
Density
Specific heat
Thermal conductivity
Viscosity (for fluid flow calculations)
Initial Temperature Setting
The pouring temperature of the molten metal is
.defined
This temperature depends on the chosen alloy
.and casting conditions
Accurate temperature input is critical for
predicting filling time, flow behavior, and
.solidification
Role Assignment
The selected volume is officially marked as the
.Cast part in the simulation
ProCAST uses this role to apply physics models
such as fluid flow, heat transfer, and phase
.change to this region
Importance of This Step
Clearly defining the cast part ensures that all
material behavior, thermal changes, and physical
.interactions are correctly applied
It allows the simulation to differentiate between the
casting and other system components (mold, die,
.chills)
Mistakes in this step can result in inaccurate results
.or failed simulations
This step is foundational for all later stages such as
mold filling, solidification analysis, and stress
prediction. It ensures the software understands which
part of the model represents the final product being
.cast
Processing in Viewer
Once all the setup steps are complete — including meshing,
defining cast and mold parts, assigning materials, and setting
boundary conditions — the next stage in ProCAST is to launch
the simulation and use the Viewer to monitor progress and
.review results
Launching the Simulation
Final Validation
Before starting the simulation, a full check is done to
ensure that all parts are correctly defined (Cast, Mold,
Ingate, etc.), and that there are no errors in mesh
.connectivity or physics definitions
Warnings and errors from the system are reviewed and
.corrected to avoid simulation failure
Solver Selection and Initialization
The appropriate solver is selected based on the
simulation type (e.g., filling, solidification,
.thermal stress)
Simulation parameters such as time steps,
.convergence criteria, and end time are set
The solver then begins calculating the physical
behavior of the casting process — this includes
molten metal flow, temperature evolution, and
.solidification progression
Monitoring the Run .1
During simulation, ProCAST provides real-time
updates through a log window showing progress,
.time step information, and calculation status
Depending on mesh size and model complexity,
simulations can take from several minutes to
.several hours
Viewer: Visualizing Simulation Results
The Viewer tool in ProCAST is used to analyze and
interpret the simulation results through graphical
outputs. It allows engineers to understand what is
.happening inside the mold during and after casting
Loading Simulation Results
Once the simulation is complete, the result o
.files are opened in the Viewer module
:Various result types are available, including o
Temperature distribution
Filling sequence (flow of molten metal)
Solidification timeline
Hot spots
Shrinkage porosity prediction
Velocity vectors of metal flow
Cooling curves
Time-Based Analysis
Results can be animated over time to show how
the mold fills and where solidification begins and
.ends
:This helps in identifying potential issues like
Incomplete filling
Air entrapment
Premature solidification
Cold shuts or misruns
Cross-Section Views and Probes
The Viewer allows cutting through the casting
.geometry to inspect internal behavior
Probes can be placed at specific points to track
.temperature, velocity, or solid fraction over time
Exporting Results
Key images and data can be exported for
.documentation and reporting
This is useful for comparing design iterations or
.justifying design choices
Importance of Viewer and Simulation Step
This stage is where the benefits of simulation become
clear. By visualizing internal behaviors that are
:otherwise invisible in real casting, engineers can
Predict and fix defects before production
Improve casting design
Optimize process parameters (like pouring
temperature and mold layout)
Save time, material, and energy
Thermal Temperature.1
Solidfication Process-2
Results
Parameter Start End Total
Fill time 0 12 12
Solidification Time 12 717 705
Maximum Temperature C 1000
Liquid Temperature C 615
Solid Temperature C 557
Minimum Temperature C 38
Maximum Filling percentage 98%
Conclusion
using ProCAST to simulate and analyze the casting process. Key
steps included 2D and 3D meshing, defining materials, and
setting up simulation conditions. The software provided clear
insights into mold filling, solidification, temperature distribution,
.and defect prediction
Using the Viewer, simulation results were visualized and
evaluated, helping identify potential issues like shrinkage and
incomplete filling. This reduced the need for physical trials and
.improved the overall casting design
In summary, ProCAST proved to be an effective tool for
optimizing casting processes, improving quality, and saving
.time and resources in production planning