NOVACAST SYSTEMS AB, which supplies production process control packages for license by foundries, introduced a new version of its casting simulation software, NovaFlow&Solid, which it called “the fastest casting simulation software ever.” NovaFlow&Solid 6.0 includes a new adaptive multi-mesh technique and a “Good Guys’ Index” (GGI) that organizes and compares analytical results.
NovaFlow&Solid 6.0 is a casting process simulation tool that uses Finite Volume Mesh technology (FVM) to visualize the prospective results of a specific gating and feeding systems, and simulates mold filling and solidification. The program simulates most commercial casting methods, according to the developer, and can reference all types of mold and core materials.
It noted also that the new adaptive multi-mesh technique reduces simulation time by 50%.
“With the new technique you use the mesh resolution needed for different parts of a simulation,” explained Håkan Fransson, product manager for NovaFlow&Solid. “The time-saving comes from switching mesh in the simulation and during filling in several steps. Where the sections are thick-walled you use a bigger mesh resolution, and for sensitive areas you use a finer mesh.”
He continues: “Now there is no excuse for not using simulation. Shortening simulation time is crucial for the foundries to be able to optimize all their castings.”
Simulation software is an important resource used by foundries to simulate an actual casting steps, and to analyze results in order to detect flaws or inefficiencies during flow filling and solidification. Any errors detected during simulation (e.g., porosity, stresses, and gas entrapment) can be corrected prior to the start of series casting.
When the results from the simulation analysis are in line with quality requirements the piece goes into production.
NovaFlow&Solid 6.0’s Good Guys’ Index compares optimized simulations and visualizes the financial and environmental effects of implementing those, such as energy consumption and CO2 emissions.
“This is an important step toward NovaCast’s vision,” offered Camilla Sjögren, marketing manager at NovaCast. “With our systems the foundries secure their quality, at the same time as they are guided toward reducing their environmental footprint. You see, green business is good business for everyone.”