CFD SIMULATION FOR INDUSTRIAL APPLICATIONS

Metal Casting Simulation

We perform CFD simulation studies for metal casting. We can study any casting process: gravity, high pressure, low pressure, centrifugal casting, etc. We use the best tool in the market: FLOW-3D Cast ®

Our Capabilities in this area are:

1. Filling simulation
2. Solidification simulation
3. Simulation of blowing of sand cores
4. Simulation of residual stresses by thermal effects
5. Study of location of vents, riser, cooling channels, sleeves, etc.
6. Optimization phases in high pressure injection HPDC
7. Report on recommendations and improvement

FLOW-3D Cast ® has proven in casting and research centers to be the most accurate tool in the market to predict the behavior of metal during filling and solidification. It has been verified in many benchmarking with real parts where the simulation matched with the reality.

The dynamics of high-temperature metal is very complex. For that reason, we need accurate simulation tools. Otherwise, the results are not adequate and the conclusions can´t use in the productive process.

Laser Welding Simulation

We carry out CFD simulation studies for laser welding simulation. For that purpose, we use the best tool in the market: FLOW-3D Weld

FLOW – 3D Weld can get powerful insights into the laser welding process and helps to achieve process optimization. With better process control it is possible to minimize porosity, heat affected zones and control the micro-structure evolution. FLOW-3D Weld is suited to simulate the complex weld simulations because of its free surface tracking algorithm.

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Advantages of laser welding respect to other welding methods:

• Better resistance.
• Less thermal condition.
• More precision.
• Minimal deformation.
• It allows to work with different materials: steel, aluminium, titanium, etc.
• The quality of the laser welding process can be simulated and predicted at a microscopic level.

The WELD Add-on module was developed to incorporate relevant physical models into FLOW-3D such as the heat fluid produced by laser source.

Additive Manufacturing Simulation

We carry out CFD simulation studies to additive manufacturing. Therefore, we use the best tool in the market: FLOW-3D ®

The three main manufacturing processes of metal additives are:

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Laser-powder bed fusion processes

FLOW-3D’s physical models simulate the melt pool phenomena at the meso-scale by accounting for particle size distribution and packing fractions while simultaneously solving for the mass, momentum and energy conservation equations.

FLOW-3D’s add-on modules DEM and WELD are used to simulate the full powder bed fusion process. The various stages in a L-PBF process are powder bed laying, powder melting and solidification and subsequently, the laying of fresh powder on the previously solidified layer, and once again melting and fusing the new layer to the previous layer. FLOW-3D can be used to simulate each of these stages.

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Direct energy deposition

Using FLOW-3D’s built-in particle model direct energy deposition processes can also be simulated. By specifying the powder injection rate and the heat flux incident on the solid substrate, the solid particles can add mass, momentum and energy into the melt pool.

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Binder Jetting 

Binder jetting simulations provide insights into the spreading and penetration of the binder in the powder bed, which are influenced by capillary forces. Process parameters and material properties directly influence the deposition and spreading process.

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In the melting process of the powder base and direct energy deposition, you can use a laser or electron beam as a source of heat. In both cases, the metal, in the form of powder for PBF and powder or wire for processes DED, melts completely and merges to form parts layer by layer.

However, in the injection of binder, a resin is selectively deposited which acts as an agglutinating agent on metallic powders to form parts to layer. These parts are sintered to achieve better densification.

Simulation of injection of plastic materials

We carry out studies of CFD Simulation for injection of plastic materials into mold. We can study any injection process in the market. For that purpose, we use the best tool in the market: Moldex3D

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Our Capabilities in this area are:

1. Filling simulation
2. Compression simulation
3. Cooling simulation
4. Simulation of residual strains and deformations

We can simulate the next process:

1. Compression Molding(CM)
2. Injection Compression Molding(ICM)
3. Power Injection Molding(PIM)
4. Gas-Assisted injection molding(GAIM)
5. Water-Assisted injection molding(WAIM)
6. Co-Injection Molding
7. Bi-Injection Molding
8. Foam Injection Molding
9. Resin Transfer Molding(RTM)
10. Chemical Foam Molding

The software  Moldex3D has proved in injection companies, mold makers and research centers to be the most accurate tool in the market to predict the behavior of the material during filling and solidification. In many benchmarking with real pieces, it has been verified that the simulation corresponds to the reality.

It is essential to have precise tools for simulation. Otherwise, if the results are not adequate,  the conclusions won´t serve in the productive process.