TECHNICAL DETAILS OF

FEM based CASTING

SIMULATION SOFTWARE –
ProCAST
 Technical Features & Specifications
ProCAST
A brief explanation of ProCAST features and applications.
Analysis
Thermal only
Flow coupled Thermal
Microstructure Analysis.
Stress Analysis.
Ability to simulate Sand casting, Shell Casting, Gravity Die Casting, High Pressure & low pressure Die Casting
Ability to simulate all castable Alloys, Fe, Al, Ni, Cu, Co, Zn, Ti, Mg.
Extensive material property Database for Casting Alloys, Sand material, Refractories, Die Material, Chill Material,
Filter, Exothermic and Insulation Sleeves.
Provision for User to create his own material properties for sand Casting Alloys, Dies, Chills, Refractories Filter,
Exothermic and Insulation Sleeves.
Thermodynamic databases are available for Ferrous Alloys and Non Ferrous alloys. (This facility is unique only to
ProCAST, and all calculations are scientific and based on the most popular Schiel and Lever Models)
Based on chemical composition (input from user), ProCAST automatically calculates temperature dependent
thermal and fluid properties for Fe Alloys and Non Ferrous alloys, Properties calculated are, Thermal
Conductivity, Enthalpy, Density, Viscosity, Fraction Solid, Solidus and Liquidus)
Automatic Shell Generator available. Options are available for both Investment Castings and Shell Moldings.
Shells of different thickness can be generated. (Only software to do so)
Cooling lines can be modeled for Die Castings.
Results display on surface of casting and Die, Inside Casting, any cross section, user defined sections. Provisions
for automatic scanning through the model for user defined thickness sections in X, Y & Z direction.
Temperature distribution of molten metal during filling, Temperature Distribution throughout casting / mold / die.
 ProCAST
Velocity vectors – Rate at which Metal hits Mold / Die to predict sand Inclusions in sand castings and
heat checks in die castings
Air Entrapment during filling – Aids in Gating & Venting location.
Solidification Pattern throughout casting surface & inside casting with cut off (X – Ray) option.
Facility to generate Animations (AVI, GIF format) & screen shots.
Graphics & contours for Nodal Temperature, Pressure & Velocity.
Inbuilt templates for thermal Analysis, Flow coupled Thermal Analysis, Sand Casting, Die Casting,
Die cycling. Provision for user defined templates for any process / Analysis.
Prediction of solidification Time, Isochrons, Mapping factors, RGL based on Niyama criteria, cooling
curves, Dendrite Arm Spacing.
Symmetry (1,2 symmetries, Rotational) Modeling to save time, 2D Model/Mesh/Simulation for faster
understanding of software features, virtual mold Algorithms for sand casting.
Porosity: can be visualized in the Post processor. Other than the Shrinkage Porosity Plot, different
options are available to view the Porosity results. It can be seen in form of Fraction Solid, Niyama
Criteria, Isochrons, and Solidification Time. All these options can be viewed in form of Surface, Cut-
off (X-RAY), Slice, and Scanning through the model.
ProCAST can take in any of the following formats from the CAD systems - Para solid, STEP, IGS,
and STL files. Provision is also made to take mesh files generated from Meshing software. It can
accept both surface and volume mesh form of Patran and Ideas mesh and surface mesh from Ansys.
An inbuilt automatic volume mesh generator called Meshcast is provided along with software.