Thermal stresses during cooling are modeled so that you can analyze resulting distortions which may cause parts to fall out of tolerance.
Gaps and interference between the casting and metal mold can be predicted and their effects on temperature during cyclic thermal and solidification can be accurately modeled.
Temperature not including Gap
Temperature including Gap
Mold distortion identifies issues which may occur from the expansion and contraction of metal mold components. The potential lifespan of metal molds can be evaluated allowing you to make design changes that can increase the life span of the mold before it is even cut.
Over time, warped dies can put additional stresses on castings, causing defects and requiring re-tooling or complete replacement. Simulation can reveal these issues before they occur, identify underlying causes, and suggest remedying tooling adjustments.
The flexibility and robustness of the FEM mesh combined with advanced mesh coarsening enable the simulation of particularly large, challenging geometry. There is no practical limit on the size of the model to be simulated.
Flash is a common indicator of a variety of issues with a mold design. The success of an initial development process for a casting is often defined by the prevalence of flash. Several costly iterations of re-tooling and machining are often necessary for its elimination.
Designers often utilize Mold Distortion simulations to help minimize or correct for mold distortion, but previously they had been unable to visualize the object of their efforts, the flash itself. By analyzing and aggregating the distortion results for multiple mold components, the software directly provides a rendering of the predicted flash.
Use powerful tools such as 6-Point Alignment to analyze distortion results and calibrate with real-life results for precise quality control.
Distortion results produced by the Stress software can be combined with Porosity results to diagnose locations which are likely to experience thermal crack.