ESI ProCAST - Simulate Die Casting Processes Software
ProCAST is a best-in-class casting simulation software, enabling foundries to evaluate, validate and master their casting processes, down to fine-tuning multiple process variations. It covers a wide range of die casting processes used in the automotive, land transportation, heavy machinery, and cross-industry supply chain, from High-Pressure Die Casting (HPDC) including Hot/Cold DCM variants to Vacuum, Low-Pressure Die Casting (LPDC), CPC, GDC/PM, Tilt/Rotacast and Semi-Solid.
- Whilst integrating advanced physics, ProCAST is proven for delivering accurate results in a very short time.
- Extensive Material Database spanning most alloys (Al, Cast Iron, Cu, Mg, Ni, Zn) and molding materials (Dies, Cores, Ceramics, Filters, Insulation & Exothermic Sleeves) to best support the specific needs of different die casting processes.
- Intuitive User Environment with dedicated Foundry Application Oriented Workflows for Gravity Die Casting, Low-Pressure Die Casting & High Pressure Die Casting.
Estimate castability risks early by facilitating `Design For Manufacturing`, and bridging the gap between OEMs and their suppliers
- Evaluate numerous design alternatives at an early stage (including materials influencing quality specification)
- Assess critical areas to achieve specific mechanical characteristics
- Reduce process development time to produce a sound casting with optimal costs and lead-time
- Enable co-design to achieve best castability
Understand the injection system by looking at the full casting cycle from the furnace to the final casting
- Analyze air entrainment in the sleeve
- Optimize the slow shot
- Determine the right switching point
- Find the right runner balancing, overflow & vent positioning
- Evaluate the effect of heat loss (misrun)
- Understand the effect of counter-pressure and vacuum on filling and gas porosity
- Account for the effect of max machine pressure on piston velocities (real-time piston control)
Optimize your die design and die casting process with confidence
- Align die temperatures with reality
- Establish stabilized die temperature
- Improve the spraying & blowing virtualization
- Account for a realistic flow of the heating/cooling media inside the die channels
- Spot & measure shrinkage porosity accounting for the intensification phase & squeeze pins
- Virtual Dimensional control
- Track thermally induced stresses through the process
- Export the simulated part for the dimensional check as in reality (eg: integrated with GOM)