Consulting Services                                  Phone:  248.624.9957

EKK can optimize your casting process:

Through the use of CAPCAST (our Finite Element Method (FEM) based Solidification/Thermal, Filling, Stress, and Porosity analysis tools) we can optimize your casting process.

Using our solidification analyses, EKK, Inc. can provide riser and casting design recommendations to avoid expensive casting concerns.

Using our thermal analysis programs we can provide cooling line placement and die design recommendations.

Filling analyses of the entire gating system and casting cavity can be provided.

For high pressure die casting we can provide a recommended velocity profile using a unique shot sleeve simulation.

We also can track and describe quantitatively areas of high porosity. 

CAPCAST is a fully automatic mesh generator that can create mesh in the casting and the mold simultaneously. The mesh construction time, which is one of the biggest bottle-necks in any FEM analysis, is drastically reduced. Thus, you can get the analysis results in a shorter period of time. Both our software development and consulting services are performed at the same facility so we can tailor our software and services to your specific process and analysis needs.

Process Simulation Models:

High Pressure Die Castings with or without a vacuum
High Pressure Die Castings with shot sleeve analysis
Various Low Pressure processes
Semi-Solid, Thixomolding processes
Permanent and Semi-permanent Casting processes
Squeeze Castings
Green Sand Castings
Hard Sand Castings
Centrifugal Castings
Structural Investment Castings

Other Options Available

Typical Materials Used:

Cast Alloys
Aluminum Cast Alloys, Ductile Cast Iron, Steel cast, Zinc Alloys, Magnesium (esp. in thin walled high pressure or thixomolded processes)

Mold Materials
H13 Steel, Green Sand, Copper, Anviloy, TZM
Typical information required from the customer
CAD or drawings of both the casting and mold
Initial conditions such as pouring temperature and inlet flow conditions
Process parameters such as cycle times and shot velocity for die casting
Materials used for casting, mold, and inserts

What You Can Expect From EKK, Inc.

EKK, Inc. will perform the consulting projects by using CAPCAST.  From this, EKK can provide information such as solidification animations, filling animations, and animations of fluid velocity during the filling.  Fluid temperature animations can be made for a filling analysis incorporating heat transfer between the cast alloy and the mold.

In addition to various animations, EKK can also provide images of temperature variations in both the mold (esp. in die casting processes) and casting at various stages in the process.

This is just general information that is available from a typical consulting project.  Residual Stress animations, and porosity images are among the many other results available from using CAPCAST software.

Please see the quick examples section below to see various images and animation results.

Reference :
Modeling of the Die Cast Process   -This article appears in the November,  1996 issue of
Die Casting Engineer from NADCA. [color  figures, analysis results, references, abstract]

Technical Paper   - An Application of 3-D Solidification Analysis to Large Complex Castings