BFP engineering team use the advanced casting simulation software to predict and optimize potential aluminum casting defects such as porosity, air entrapment and solidification issues at an early stage of process development, to minimize the trail and error costs with maximized casting quality.

With deep knowledge of the simulation technologies, BFP engineering can predict and evaluation the entire casting processes, from the part draft angle analysis, tooling layout all the way to the mold filling, solidification and cooling. And the result is better gating, venting and cooling system design before making every mold.

The effective simulation process for casting optimization

Down below is an example of standardized casting simulation process performed at BFP Castings.

OP: Casting simulations start with the part 3D CAD model feasibility review, generally including the draft angle, parting line and thickness analysis.

OP: The filling simulation shows how liquid metal flowing through the gate to fill the mold cavity.

OP: Here is the air pressure analysis, identifying areas where air is entrapped in the cavity during the filling process allows an optimized gating design and an effective placement of vents and overflows.

OP: Then following with solidification simulation accurately predicts the metal’s gradual transition from fully molten to a partially and then fully solidified state.

OP: The porosity simulation predicts and identifies the locations of porosity in the casting. With this information, our engineer can optimize the cooling layout and add local squeeze pins where needed.

How can your company benefit from our metal casting simulation?

Using advanced cast simulation software combined with more than 20 years metal casting devleopment experience, BFP engineers have the capabilities to simulation the following processes for your next project:

• High pressure die casting/High vacuum die casting

• Low pressure die casting

• Gravity/Permanent mold die casting

• Investment casting

Contact us today and our engineers would love to assist both in your next demanding new projects as well as in the quality improvement of existing parts.

*All consultation services are completely free of charge.