THE WORLD’S MOST POPULAR

SOLIDCAST CASTING SIMULATION SYSTEM

Why do over 500 companies and schools worldwide use SOLIDCast™? BECAUSE IT WORKS!! No other casting
simulation program offers POWER, EASE OF USE and ACCURACY like SOLIDCast.

SOLIDCast simulates castings poured in gray iron, ductile

iron, steel, aluminum, copper-base, magnesium, nickel
based and almost any other alloy. A database of several
hundred alloys, with all pertinent properties, is included.

SOLIDCast can simulate molding processes such as green

sand, chemically-bonded sand, investment and permanent
mold. You can use sleeves (insulating or exothermic),
chills, hot topping, cooling channels, heating elements and Investment Cast Shell in a Sand Bed

just about anything else that is used in the metal casting

process.

With SOLIDCast you can import 3D models from CAD, or

build your own models without CAD.

SOLIDCast contains both Gating and Riser Design

Wizards™, tools that allow you to rig new castings in just a
few minutes, using actual simulation results, not guesses
based on simple geometry. Since casting alloy, mold
material and mold inserts are all considered, there is no
more accurate way to rig a casting than with the Gating
and
Riser Design Wizards! A Single Feeding Zone in a Ductile Iron Casting
Analyzed with the Riser Design Wizard
Graphics are the most sophisticated available, with fully
movable 3D models, X-ray images, high-resolution color
plots and AVI video files. Send movies to anyone with a
Windows PC!

SOLIDCast lets you see how your casting will solidify

before you make patterns, dies and costly mistakes. Pour
test castings on the computer, not the foundry floor! Design
gating systems and test them out before making your first
casting. Casting simulation helps you to shorten lead
times, produce higher quality and improve yield. All of
this means lower costs, higher profits and improved
marketability for your foundry.
Aluminum Rigging System Designed by the
SOLIDCast Gating and Riser Design Wizards

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 FLOW MODELING FOR MOLD FILLING USING
FLOWCAST COMPUTATIONAL FLUID DYNAMICS
FLOWCast™ is the fluid flow modeling module from
Finite Solutions, Inc. FLOWCast works in conjunction
with models created by SOLIDCast™.
Flow modeling lets you see how molten metal will flow
through gating systems and fill the mold. FLOWCast
models convection, conduction and radiation in the mold
cavity, allowing you to analyze your casting and gating
design to predict and minimize flow-related defects such
as misruns due to premature solidification, or oxide
formation or mold erosion due to excessive velocities
during filling.
Initial Filling of Iron Castings Showing Metal
Temperature in the 10 Casting Pattern Layout
Metal Velocity Prior to Misrun in two Copper Castings
CastingSimulation com
FLOWCast is a full-featured CFD (Computational Fluid
Dynamics) simulation, based on the Navier-Stokes
equations for fluid flow. With FLOWCast, you can view
progressive temperature, fluid velocity and fluid pressure
during the fill, from any angle of view.
FLOWCast is integrated with SOLIDCast and uses
models and meshes created with SOLIDCast. Since
SOLIDCast is the world's easiest-to-use casting modeling
system, flow modeling has never been easier. Just import
your casting model from 3D CAD or build your model
using SOLIDCast tools, mesh the model, and run
FLOWCast to simulate mold filling.
Results from a FLOWCast simulation can be used in
SOLIDCast to model the final solidification of the casting,
resulting in a completely integrated casting modeling
system. Design and analysis of gating and mold filling
with FLOWCast is as simple as solidification modeling
with SOLIDCast.
Flow Path Tracing in an Aluminum Sand Casting
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 OPTIMIZATION OF CASTING PROCESS DESIGN USING
OPTICAST SOLIDCast™ and HyperOpt®

OPTICast™ is an amazing software tool that works in
conjunction with the SOLIDCast™ solidification modeling
system. OPTICast uses the HyperOpt® system from
Altair Engineering, Inc., the leader in the field of
optimization software.
Using OPTICast, the foundry engineer can start with an
initial design and allow the computer to do the work of
modifying the design and running simulations to achieve an
optimum result.

“X-ray” view showing

simulation of current “X-ray” view showing
riser feeding simulation of optimized
riser feeding

Original Riser Design

Cast Iron Casting with Optimized Riser Design

What does OPTICast do?

OPTICast actually automates the simulation process! Start
with an initial design for a casting, with gating and risering,
typically created in the SOLIDCast modeling system, using
the Gating and Riser Design Wizards™. Then select the
following elements:
Design Variables: Design elements that are allowed to
vary. For example, the height and diameter of a riser. It
could also be the metal pouring temperature, or the preheat
temperature of an investment shell.
Now, for the first time, the technology of automated design
is brought to the foundry in the form of a practical and
easy-to-use design tool. OPTICast can help you to improve
your yield and your quality to an optimum point, while
freeing design engineers from the repetitive task of trialand-
error design.

Constraints: Used to determine whether a particular

design is acceptable. For example, the foundry engineer
might specify a minimum acceptable yield percentage, or a
maximum acceptable level of macroporosity.

The Objective Function: States what the foundry engineer

is trying to achieve. Examples might be to maximize the
yield, minimize shrinkage or minimize solidification time.

Once these elements are identified, the user then launches

an Optimization Run. This consists of a series of
simulations in which the design conditions are varied under
the control of HyperOpt, model changes are made and
simulation results are evaluated, all completely 12% yield improvement, automatically,
automatically, until the desired result is achieved. with guaranteed casting quality!

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