Design Services
Simulation services for the optimization of foundry processes

Simulation services
Simulation of foundry processes helps provide the foundryman with relevant information for designing agravity die cast or sand cast mold. Pouring systems, overflows, vents and risers can all be optimized inthis way. A precise representation of these aspects, by taking not only cooling and heating measures but
also cycle times into account, enables such problems as shrinkage cavities, veining and many othercasting defects to be avoided.
The simulation services of ASK Chemicals offers you comprehensive technical know-how and understanding combined with state-of-the-art simulation programs (MAGMA®, FLOW-3D and ARENA-FLOW®)
in order to give you the best possible support with your casting processes. Besides the simulations, we
provide help with the design of castings, tools and your complete process – consistent with our maxim:“We advance your casting”!

The advantages to you at a glanceShorter product rollout times and, consequently,
faster time to market
Clear time-saving in the design of patternplates, core boxes and molds

Core making:Higher productivity due to perfect coresand optimized catalyst consumption
Design of your core making process, includes
INOTEC

Casting simulation:
Calculation of optimum feeding
Less scrap due to casting defects

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“Simulation forPERFECTCASTING RESULTS!”|3

Simulation

Core shooting

3D view

Simulation of the core shooting process enables defects in the core to be predicted. The resulting
sand compaction, the flow path of the sand, pressure and speed are all used in the evaluation.

Core shooting simulations at a glance	Visualization of complex shooting processes 	
Visualization of non-filled or insufficiently filled areas	Visualization of areas of increased tool wear

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Example – Shooting head performance
The simulation represented here depicts the less than ideal draining of the shooting head as a result of the given tool design.

Sequence 1

Sequence 2

Sequence 3

Completely filled shooting
head before the shot

Mixing of the sandduring the shot

Inadequately filled cores due topoor supply of sand to the shooting
nozzle at the edge

Example – Time-dependent packing density [kg /m³]
The simulation of the shooting process visualizes the filling process and displays areas of varying compaction.

Sequence 1

Sequence 2

Sequence 3

Empty core tool

Incompletely filled core tool

Completely filled core tool

Benefits at a glanceOptimization of injection
nozzles and positions
Optimization of vent nozzles
and positions
Optimization of shooting pressure
and tool design, incl. the designof the shooting head|5

Simulations

Core gassing and hot-air induction

Time-dependent gassing behavior
Red: area not yet gassed
White: 100% fully gassed area

Simulation of the core gassing and hot-air induction processes enable inadequately cured areas to bevisualized and eliminated through deliberate modification of the CAD setup. We are systematically developing optimization approaches for you to improve the gassing times and reduce catalyst consumption.

Core gassing simulations at a glance	Visualization of the flow conditions	Visualization of the gas pressures	Visualization of inadequately gassed areas

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Example – Core gassing before optimization

Sequence 1

Sequence 2

Sequence 3

Core before gassing

Gassing behavior

Uncured area after gassing> 10 sec.

Example – Core gassing after optimization

Sequence 1

Sequence 2

Sequence 3

Core before gassing

Gassing behavior

Core completely gassed ≤ 4 sec.

The information from the core gassing simulation made it possible to optimize the position and number of gassing nozzles andvents. A fully cured core is the result: cycle time saving.

Benefits at a glanceOptimization of the gassing
setup and gassing pressure
Optimization of venting
Optimization of cycle time andcatalyst consumption|7

Simulation

Mold filling

Temperature distribution after mold filling

Simulation of the mold filling process allows conclusions to be drawn about the functionality of theriser and gating system. The focus here is on temperature and flow speed distribution, cold laps, airentrapment and mold erosion.

Mold filling simulations at a glance	Visualization of the temperature distribution 	
Visualization of the flows, turbulences, areas of risk	Visualization of cold laps, hot tears and mold erosion	Visualization of air entrapment
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Example – Optimization of the temperature distribution
during mold filling

Sequence 1

Sequence 2

Sequence 3

Unfilled mold

Partly filled mold

Completely filled mold, very cold temperature of the cast metal after mold filling

Benefits at a glanceOptimization of the riser andgating system
Optimization of the model designs
Optimization of the casting
parameters|9Simulation

Solidification

The solidification simulation indicates hot spots

ASK Chemicals simulates optimum feeding, taking thermo-physical values and riser geometries asa basis.

Solidification simulations at a glance	Visualization of solidification behavior and cooling 	
Visualization of shrinkage-induced porosities	Visualization of microstructures

10 |Example – Solidification without riser
During the transition from the molten to the solid state, core volume traction (solidification shrinkage) occurs for mostmetallic substances and alloys. This can cause cavities and other casting defects to form.

Sequence 1

Sequence 2

Sequence 3

Start of the casting simulation

Distribution of metal (yellow)

Cavity formation in the casting
after solidification (blue)

Example – Optimized solidification with riser
The volume deficit produced in the mold cavity needs to be counterbalanced by post-feeding with still molten metal.
This occurs with the aid of risers. The simulation reveals that the cavity formation has now relocated to the riser.

Sequence 1Sequence 2

Sequence 3

Start of the casting simulation

Distribution of metal (yellow)

Cavity formation in the riser
after solidification (blue)

Benefits at a glanceOptimization of the riser andgating system
Optimization of the chilling strategy
Optimization of the output
Optimization of the mechanicalproperties| 11

The following marks are registered by ASK Chemicals GmbH, ASK Chemicals Metallurgy GmbHor ASK Chemicals LLC in one or more countries:
ALPHASET, ASKOBOND, ASKRONING, ASKURAN, BERANOL, BETASET, CERAMCOTE,CHEM-REZ, DENODUL, DISPERSIT, ECOCURE, ECOPART, EXACTCALC, EXACTCAST,EXACTFLO, EXACTPORE,FLEXPOUR, GERMALLOY, INFORM, INOBAKE, INOTEC, ISOCOTE,ISOCURE, ISO-FAST, ISOMAX, LINO-CURE, MAGNASET, MIRATEC, NOVACURE, NOVANOL,NOVASET, OPTIGRAN, OPTINOC, PEP SET, REMMOS, SMW-INSERT, UDICELL, VEINO,VELVACOAT, ZIP-CLEAN, ZIP SLIP.

ASK Chemicals L. P.
495 Metro Place South
Suite 250
Dublin, OH 43017
Phone: +1 800 848 7485
Fax: +1 614 761 1741
info.usa@ask-chemicals.com
www.ask-chemicals.com

This information is based on our current state of knowledge and does not represent assurance of the properties of the products described. We are only liable for
product-related advice and information within the scope of duties of disclosure included in collateral contractual agreements unless expressly agreed otherwise. (05 / 15)

Visit www.ask-chemicals.com/trademarks for a complete list of our trademarks.
Please contact ASK for any questions concerning the usage of these marks.