Premium Consulting

Typical information required from customer:

∞ CAD or Drawings of both the castings and mold
∞ Initial conditions such as pouring temperature and inlet flow conditions
∞ Process partimeters such as cycle times and shot velocity fordie casting
∞ Materials used for casting, mold and inserts

Simulation Results Provided

ESSENTIAL VS PREMIUM

Through the use of CAPCAST (our FEM based Thermal/Solidification,
Flow, Porosity, and Stress Analysis Tools) we can optimize your casting
process.

¤ Reduce Tooling and Development Lead Times
¤ Reduce / Prevent Scrap
¤ Reduce Cycle Times
¤ Increase Tool Life
¤ Educate Process Engineer

Flow Analysis

¤ Filling Pattern Animations (AVI/GIF)
¤ Fluid Front
¤ Velocities
¤ Temperature (Coupled w/ Thermal Analysis)
¤ Trapped Gas/Oxide Defects
¤ Particle Tracking
¤ Air/Back Pressure
¤ Filling Rate/Time Verification
¤ Predict Cold Shuts
¤ Recommendations on fill
pressure/fill rate/overflows/venting/ temperature

Porosity Prediction Analysis

¤ Microporosity
¤ Analyze mechanical properties
of the casting for reference

Thermal/Solidification Analysis

¤ Temperature plots of the casting/mold
¤ Solidification Animation (AVI/GIF)
¤ Solidification Time Verification
¤ Shrinkage (Hot Spots)
¤ Recommendations on gating/riser /chill/cooling locations

Stress/Distortion Analysis

¤ Deflection/distortion of the casting after ejection/removal from mold
¤ Identify interference/gap problems on molds
¤ Analyze thermal fatigue of mold

Process Simulation Models:

¤ High Pressure Die Castings with or w/o a vacuum
¤ High Pressure Die Castings with shot sleeve analysis
¤ Various Low Pressure Processes
¤ Semi-Solid, Thixomolding Processes
¤ Permanent and Semi-Permanent Casting Proccesses
¤ Squeeze Castings
¤ Green Sand Castings
¤ Hard Sand Castings
¤ Centrifugal Castings
¤ Structural Investment Castings
¤ Other Options Availab

Typical Materials Used

Ca:st Alloys:

∞ Aluminum Cast Alloys
∞ Ductille Cast Iron
∞ Steel Cast
∞ Zinc Cast
∞ Magnesium (esp. in thin walled high pressure or thixmolded precesses)

Mold Materials:

∞ H13 Steel
∞ Green Sand
∞ Copper
∞ Anviky
∞ TZM

EKK's SmartMesh generator can create a mesh with the casting, mold, and other components (sprue, chills, cooling lines, gating, etc.) 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.

Using our solidification analyses, we 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 analysis of the entire gating system and casting cavity with thermal analysis to the mold can be provided.For high pressure die casting, we can provide a recommended velocity profile using our moving shot sleeve simulation.We also track and describe quantitatively areas of high porosity.

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. Go to the software link to see some samples of the analysis that EKK can provide.






		Typical information required from customer: ∞ CAD or Drawings of both the castings and mold ∞ Initial conditions such as pouring temperature and inlet flow conditions ∞ Process partimeters such as cycle times and shot velocity fordie casting ∞ Materials used for casting, mold and inserts Simulation Results Provided
ESSENTIAL VS PREMIUM Through the use of CAPCAST (our FEM based Thermal/Solidification, Flow, Porosity, and Stress Analysis Tools) we can optimize your casting process. ¤ Reduce Tooling and Development Lead Times ¤ Reduce / Prevent Scrap ¤ Reduce Cycle Times ¤ Increase Tool Life ¤ Educate Process Engineer		Flow Analysis ¤ Filling Pattern Animations (AVI/GIF) ¤ Fluid Front ¤ Velocities ¤ Temperature (Coupled w/ Thermal Analysis) ¤ Trapped Gas/Oxide Defects ¤ Particle Tracking ¤ Air/Back Pressure ¤ Filling Rate/Time Verification ¤ Predict Cold Shuts ¤ Recommendations on fill pressure/fill rate/overflows/venting/ temperature Porosity Prediction Analysis ¤ Microporosity ¤ Analyze mechanical properties of the casting for reference	Thermal/Solidification Analysis ¤ Temperature plots of the casting/mold ¤ Solidification Animation (AVI/GIF) ¤ Solidification Time Verification ¤ Shrinkage (Hot Spots) ¤ Recommendations on gating/riser /chill/cooling locations Stress/Distortion Analysis ¤ Deflection/distortion of the casting after ejection/removal from mold ¤ Identify interference/gap problems on molds ¤ Analyze thermal fatigue of mold
Process Simulation Models: ¤ High Pressure Die Castings with or w/o a vacuum ¤ High Pressure Die Castings with shot sleeve analysis ¤ Various Low Pressure Processes ¤ Semi-Solid, Thixomolding Processes ¤ Permanent and Semi-Permanent Casting Proccesses ¤ Squeeze Castings ¤ Green Sand Castings ¤ Hard Sand Castings ¤ Centrifugal Castings ¤ Structural Investment Castings ¤ Other Options Availab	Typical Materials Used Ca:st Alloys: ∞ Aluminum Cast Alloys ∞ Ductille Cast Iron ∞ Steel Cast ∞ Zinc Cast ∞ Magnesium (esp. in thin walled high pressure or thixmolded precesses) Mold Materials: ∞ H13 Steel ∞ Green Sand ∞ Copper ∞ Anviky ∞ TZM	EKK's SmartMesh generator can create a mesh with the casting, mold, and other components (sprue, chills, cooling lines, gating, etc.) 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. Using our solidification analyses, we 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 analysis of the entire gating system and casting cavity with thermal analysis to the mold can be provided.For high pressure die casting, we can provide a recommended velocity profile using our moving shot sleeve simulation.We also track and describe quantitatively areas of high porosity. 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. Go to the software link to see some samples of the analysis that EKK can provide.