PROCESSES SIMULATED:

Does the software work for high pressure die cast applications, both aluminum and magnesium?
Yes. CAPCAST was written with HPDC in mind, but it is applicable to all casting processes. In addition to Mg and Al, the software has databases for Fe, Zn, Stainless Steel, to name a few. CAPCAST has a successful history with aluminum high pressure die casting simulation. CAPCAST was selected as the simulation software of choice for the USCAR Structural Cast Magnesium Development project. EKK is working closely with the other USCAR project team members in the development of the magnesium high pressure engine cradle casting. We have extensive experience using our software to model the following processes: High Pressure Die Cast (with/without vacuum), Squeeze Cast (Direct & Indirect), Gravity Permanent Mold, and Semi-Permanent Mold, Low Pressure Processes, Green Sand, Hard Sand, SSM and Thixomolding, Structural Investment Casting and Centrifugal Casting. At the current time, we do not have the ability to model directionally solidified investment casting (i.e. single crystal castings).

Can your system model a variety of alloys?
Yes, material properties including the latent heat curve of the solidifying material are entered into the analysis software. EKK provides its users with data for the most popular alloys, but the user is not limited to these materials. This data can vary with time or temperature.

Can your system model a variety of Mold Materials?
Yes, material properties of differing mold materials (i.e. permanent mold, sand) are also entered into the analysis software. This is true for different materials within the same mold, i.e. inserts, chills, etc.

With whom do you have experience in the Die Cast & Squeeze Cast processes?
To name a few. . . . Die Cast: Gibbs, JL French, Lunt, Metaldyne Squeeze Cast: Ube Industries, CMI International , GM SPM & Low pressure: Hayes Lemmerz, Grenville

Does your system have the capability to convert 3D wire frames to solid models? Are there any other auxiliary hardware/software items which would need to be purchased in order to perform a thorough analysis (i.e. A solids modeling package?)
Our mesh generator does not use solid models to generate a finite element mesh. We use STL format to import CAD data. Most CAD programs can output STL files. We use third party software to convert IGES/UG/Catia to STL in our consulting projects.

POROSITY:

Does the software determine porosity problems and locations?
Yes. Our porosity prediction software is highly accurate in Al and Fe applications. It is recommended for Low Pressure, SPM, and Gravity casting processes. In high pressure die casting, we found the location of porosity agrees well with our trapped gas analysis. In a recent USCAR project, a large scale magnesium cradle casting proved that our trapped gas results showed precisely where porosity would occur. EKK authored an article in the May 2003 edition of Die Casting Engineer magazine regarding this topic.

If so, how does the software show you?
There is a post processing interface included that allows you to see all your results. You are able to see the distribution of trapped gas in an animated view.

Is there a separate module for this?
Technically, yes. Our porosity prediction software is a separate program, but it is included with our thermal analysis software. As stated above, we recommend using the trapped gas analysis for porosity predication in the high pressure die casting process. This trapped gas is part of the standard CAPCAST fluid flow package.

SOLIDIFICATION:

Cooling:

Does the software show results using water, oil and spray?
Yes. Our post processing software allows you to view cut sections of the mold to see the cooling line effect on the mold. You can also view results at different phases of the production cycle to monitor die temperatures.

Does your system have solidification modeling capability?
Yes, CAPCAST has a three-dimensional heat transfer program with the ability to incorporate the latent heat released during the casting process.

Does the software show thermal distortion?
Yes, we have a stress/distortion package as well. Keep reading.

How does it report it?
The program works by importing temperatures from the thermal analysis and then conducting the thermal stress/distortion analysis. All the results are viewable on our post processing interface. Animated deformation is available as well.

STRESS ANALYSIS:

Does the software do stress analysis?
Yes.

How does it report this info?
Again, our post processing software that is included with our package will display results including animated representation.

Does the software help determine the size of steel required or do you have to input some data and then the software will analyze?
It will not make explicit recommendations for you. However, once the mesh is created you have a great deal of flexibility in changing the size.

Die fatigue(Life Prediction):

How does the software do this?
Die life prediction currently focuses upon peak strain as a predictor of thermomechanical die degradation. Peak strain is found to give a good estimate of trouble spots. This model has not been verified at high temperatures as of yet. We are currently developing the database to accommodate high temperatures as well.

Does it show you visually?
We show by a contour plot of die life prediction based on peak strain.

FLUID FLOW:

How easy is it to set up a simulation?
It's quite simple really. CapFD flow simulations are setup using easy to follow graphical interfaces. Once you have a model you only need to establish a few parameters in the menu interface (alloy type, gravity direction, etc) and you are ready to go.

Can you model tilt pour castings?
Yes. See the Fluid Flow section of our Software page.

Can you simulate venting and trapped gas?
Yes. Modeling venting allows for a very accurate prediction of residual trapped gas in the casting. The simulation also allows you to model in a vacuum effect as well.

With HPDC can you use the simulation to establish proper shot parameters?
Yes. With our HPDC simulations you have the option of modeling the shot sleeve explicitly or using an velocity boundary condition at the biscuit. The software has a pre-simulation calculator that will take into account the volume of the casting and the dimension of the biscuit and give you the minimum sleeve fill and shot speed transition points for an adequate fill. From there, modeling the shot sleeve allows you to see if your velocity condition is appropriate for your process.

Is your system capable of showing flow/fill patterns in the mold?
Yes. Not only that, post processing visualization will allow you to see flow velocity vectors, temperatures, percent solid fraction, and amount of trapped gas to name a few options.

POST/PRE PROCESSING:

What are your pre & post-processor capabilities?(node generation, element geometry, result viewing)
Pre-Processor: CAPCAST's MESHID interface allows you to inspect your simulation mesh before simulation, and in some cases you can make explicit alterations to the mesh if necessary. The screen is a dynamic display that allows you to rotate and move your model in real time, making visual inspection very easy. MESHID also houses the graphical interface to set up all your thermal simulations.

Post-Processor: CAPCAST's CAPOST module has many of the same advantages as MESHID. CAPOST was designed with the casting process in mind, so several features for post-processing casting analysis results are automated and stream-lined. The post processor allows you a dynamic view of your results. It also has the capability to generate animated graphics files of your results for easy distribution.

What type of output does your system provide for shop floor use?(temperature distributions, flow patterns, etc.)
Our post-processor, CAPOST, can display various types of output. Some of the more useful (for shop floor use) are mold temperature distribution, cooling curves, solidification sequence plots (for identifying potential porosity) and mold filling sequence (for identifying potential areas of air entrapment and misruns). CAPOST can also process a variety of other types of output. You can determine the type that is most useful for your operation. We can help you in determining the most useful type of results by showing you various examples of output.

TRAINING AND SUPPORT

How long do you feel training should be?
It takes about 3 days to a week to get familiar with the software. That's the duration of our introductory training course here at our office. After that, most users are pretty comfortable using the software on their own with consistent use. We are committed to support after the initial training period. You are always welcome to email, call or visit with concerns or for help at no additional cost. For those who purchase perpetual license, the annual maintenance and support fee is required for all years following the first year of purchase.

What knowledge /education level should the person running your system have?
Currently we have users that do not have a college degree and we have users that have a Ph.D. We believe it is most beneficial for the beginning user to have some casting experience and some computer experience. We have found that it is easier to "teach" computer skills than foundry/tooling skills.

What are the costs for training at your site and the customer site?
Training at our office is included in the overall price of the software. Training at your location would be charged a per day fee plus our travel expenses. We recommend training at our facility as it enhances the overall learning experience.

How accessible is your support staff?
We like to work closely with all of our customers. We are a small company and do very little advertising. Consequently, we rely on 'word of mouth' references from our customers. We cannot afford to have any unhappy customers. We are on the phone with our customers on a regular basis. Our customers are always invited to bring specific problems to our site for review by our staff. Customers are encouraged to send us specific problems electronically (FTP,etc.). We enjoy visiting our customer sites because we can identify specific needs that can be used to enhance our software.

VERSION RELEASES

How many releases per year?
It varies. At our annual user meeting, we give our customers a complete CD with the latest version of the software. There are also minor upgrades that happen throughout the year and customers are free to retrieve those newer versions from our FTP site. We encourage input from or customers for software enhancements. We are continuously reviewing those requests and implementing them as time permits.

DEMO OF AN EXISITNG PART

Would you do a full flow layout with overflows as well as doing a stress analysis on a demo part?
We encourage you to give us an existing part that you are familiar with for a demonstration. We strongly feel that the best way to compare products is through an actual demonstration of what can be produced from one your parts. We would require that you send us the casting geometry files (preferably STL file format) and some casting process parameters. However, we normally limit this type of exercise to a relatively simple geometry or we will find it necessary to charge for some of the modeling costs to cover our expenses.

Would you be willing to provide a "real world" example in which your system was used to pinpoint and correct/improve conditions in a die cast process?
We have several examples showing problems that have been solved, particularly die castings. We also have some squeeze cast examples. Most of these case studies are examples where the casting company involved with a particular part has given us permission to use their part as an example.

Is your software 'proven'?
We feel our software has been proven on all major casting processes. In addition to selling the CAPCAST software, EKK provides a casting industry consulting service. We regularly match our results with experimental data including time - temperature cooling curves (in the casting and mold), thermal camera surface plot data, porosity correlation to sectioned castings & x-rays, and Secondary Dendritic Arm Spacing measurements.