ADVANCED CFD BASED

CASTING SIMULATION SOFTWARE

SUPPORTED

Cast-Designer from C3P Software International is a software package specially designed for
casting business, includes the casting part design and evaluation, mould design and validation and
casting production/gating optimization.

MATERIAL DATABASE

Cast Designer has more than 400 industry standard materials in the database including Cast iron,
Steel, Stainless Steel, Copper, Mg, Zn, Ni, Gold, Silver & Aluminum alloys and varieties of mould,
sand, & sleeve materials.
BUILT-IN

TOOLS & ADVISORS

Cast Designer has KBE (Knowledge based Expert

System), which has 50 years of industrial experience.

The gating system advisor is the first step in casting

system design.

BUILT-IN

TOOLS & ADVISORS

GATING DESIGN TOOLS & ADVISORS

1. Using Design Advisor/Wizard, set

runner start and end areas, etc

2. Draw your concept lines using 4 simple 3. Apply Design from Wizard, runner section 4. Runners, in-gates and sprue are created with 5. Fine tune & get final design
tools main runner, runner, gate runner and areas are copied from the design sheet design sheet values in 3D in a single click.
sprue. Adjust, if required.
GATING DESIGN TOOLS & ADVISORS

Gating
system of
automatic
part

Draw directly on the 3D parting surface

Runner design are automatically
projected to 3D Parting surface
Gating system of engine block
ADVANCED
AUTOMATIC

Before: Casting Temperature with Hot After: Casting Temperature is now

Spots with 480 C can cause Mould Stick. more balanced around 400 C can
avoid Mould Stick.

Before: Mould Temperature is After: Mould Temperature is now

below 120 C and can cause Cold 260 C and more balanced and can
shut. avoid Cold shut.

Before: Original Cooling After: Modified Cooling Channel

Channel Design Design
AUTOMATIC

Start Casting
(Start Cycle) t t2 t3 t4 t5 t6
1
T1 T2 T3

Casting
Filling Move Open Close Wait for
Take Spraying Cooling
Solidification Core Mould Mould Next Cycle
Part
AUTOMATIC

Optimization Setup:

To achieve air entrapment free flow:

Optimize the section area factor of the main
runner/main gate and sub-runner 1 (SR1) and
sub-runner 2 (SR2).
We set a factor K, if K<1 then the section area
SR1 and SR2 will be zero. Also, K will adjust the
inner gate area C and D directly. Optimization Results
AUTOMATIC

Sample Optimization:

Shrinkage Porosity
in Original Design Shrinkage Porosity
in Optimized Design

Yield = 60.55% Yield = 59.83%

UPFRONT

FIND HOT SPOTS!

IN 3 CLICKS, 3 MINUTES

STEP 1: STEP 2: STEP 3:

Import CAD model Create mesh Check MDI result
AUTOMATIC

rated
In Cast-Designer, A new Distortion Compensation Solver (DCS) was General shape Compensation module of
Cast-Designer
developed based on the mechanical stress solver to find Top OEMs use
our stress
compensation geometry automatically. module

Casting compensation is a common and useful method to correct the Original design Shape after casting

casting distortion after casting. A simple compensation is explained in this

example, but it asks rich experience, and very difficult for complex
Compensation Original shape
geometry, and DCS can help to find the compensation for complex shapes. shape achieved

Sample Compensation:

Automotive part

Example: Hot Tear:

Automotive part failed during
test due to high average
normal stress.