CASTING DEVELOPMENT PERFECTED
Meshing & Translators
Simulated Processes
Porosity
Solidification
Stress Analysis
Fluid Flow
Post Processing
Training & Support
Version Releases
Demo
Hardware Recommendations
Our software is entirely Finite Element (FEM) based. The accuracy of FEM versus finite difference is undisputed.
Not anymore. In the past, the biggest knock against using FEM was the difficulty in creating a suitable mesh. However, we developed an automatic finite element mesh generator which makes mesh creation just as easy as if you were using finite difference software. Our automatic mesh generator works directly from STL files and can create a mesh of whole mold assemblies at the push of a button.
Not at all. Finite element meshes do not need to be as dense as finite difference meshes. As a result, finite element simulations take less time, and less computer resources as well. Not only that, as real world casting parts become larger and more complex, the finite difference method becomes even less practical.
Yes. Through a PATRAN's neutral file format or IDEA's universal file format, other meshing software can be used with EKK Capcast. In the past, those who have initially used other meshing software that was originally developed for structure analysis have failed to create a mesh for HP die casting process. This is due to the complexity of the die components. By using our superior FEM mesh generator they were successful in creating a mesh and have continued to use it since
Our software works best with STL files. As long as your CAD program can export STL, everything is fine.
As mentioned above, we achieve the best results when using STL file format.
Yes, it works best when the cooling line voids are incorporated into the original CAD. However, cooling lines can also be added in later using MESHID or addition in-house CAD work, with guidance from the customer.
Yes, most of our users deal with complex part geometries that cannot be approximated by one or two dimensional modeling. However, through proper placement of boundary conditions, the analysis of two-dimensional problems is possible (and in most cases simple).
Our system models the casting, gating cores, water lines, etc. all simultaneously. This is extremely important to obtain an accurate representation of the casting process. We never perform solidification analyses without including a coupled part & mold model. However, we can de-couple the mold from the part when doing a filling analysis in those cases where the thermal effects are not important.
Yes. EKKcapcast 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. EKKcapcast has a successful history with aluminum high pressure die casting simulation. 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, and Structural Investment Casting. At the current time, we do not have the ability to model directionally solidified investment casting (i.e. single crystal castings).
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.
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.
To name a few, Die Cast: Gibbs, JL French, Lunt, Metaldyne Squeeze Cast: Ube Industries, CMI International , GM SPM & Low pressure: Hayes Lemmerz, Grenville
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.
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. EKK authored an article in the May 2003 edition of Die Casting Engineer magazine regarding this topic.
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.
Yes. However, 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 fluid flow package.
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.
Yes, EKKcapcast has a three-dimensional heat transfer program with the ability to incorporate the latent heat released during the casting process.
Yes, we have a stress/distortion package as well. (see below)
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.
Yes.
Again, our post processing software that is included with our package will display results including animated representation.
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 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.
We show by a contour plot of die life prediction based on peak strain.
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.
Yes. CAPFD has a moving-mesh capability which allows for accurate modeling of the dynamics of the liquid metal movement in the shot sleeve of a high pressure die cast machine. The effect of shot profile variations on air movement and entrapment in the sleeve can be easily evaluated.
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.
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.
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.
Pre-Processor: EKKcapcast'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: EKKcapcast'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.
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.
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.
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.
Training at our office is included in the overall price of the software. Training at your location has a small daily fee plus our travel expenses. We recommend training at our facility as it enhances the overall learning experience.
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.
It varies. Around the time of our annual user meeting, we provide our customers the latest version of the software. There are also minor upgrades that happen throughout the year. We encourage input from or customers for software enhancements. We are continuously reviewing those requests and implementing them as time permits.
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
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.
We feel our software has been proven on all major casting processes. In addition to selling the EKK 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.
Our software is supported in both Linux and Microsoft Windows operating systems.
We recommend the following as suitable for running our software:
•Processors: Intel i7 multi-core processors
•Memory: 16 GB RAM
•Hard Drive: 2 TB SATA
•Video Card: NVIDIA GeForce 760
•OS: Ubuntu LINUX / SUSE Linux