ESI Group Announces Release of ProCAST 2016 Simulation Software

ESI Group announced the new version of its casting simulation software ESI ProCAST, a virtual manufacturing solution of ESI that enables foundries to improve the design and quality of the parts they produce. ESI ProCAST predicts manufacturing defects early and without the need for costly part production. Consequently, part design and manufacturing processes can be corrected well-ahead of production, achieving lower scrap rates and delivering quality parts in a consistent way.

ProCAST 2016 promises even quicker turnaround times with new workflows dedicated to gravity casting and high pressure die casting. Set-up time for gravity casting, the most widespread sand casting process, is reduced to just a few minutes, while the workflow for high pressure die casting addressed machine selection and bridges the gap between design and production to deliver increased efficiency on the shop floor.

Casting simulation helps industrial manufacturers and foundries comply with new and increasingly stringent market expectations and achieve the highest quality and productivity possible. To that end, ESI ProCAST provides a complete solution, covering all casting processes and the alloys used in diverse industry sectors and the latest 2016 version focuses on key industrial challenges specifically related to sand, investment and die casting processes in the automotive, aerospace and heavy industries.

In regard to sand casting processes, ESI ProCAST 2016 has been enriched with a dedicated workflow for gravity casting, enabling simulation set-up within minutes. Taking all process parameters into account to deliver highly precise results, this step-by-step approach can be customized to fit any foundry’s specific requirements and processes, delivering improved usability when repeating tasks. The new functionality is easy to use and can be mastered by any foundry within a few days.

Another notable enhancement to ESI ProCAST 2016 is the introduction of the machine selection workflow that draws on a dedicated database for high pressure die casting (HPDC) machines, including the Colosio machines. The new functionality enables the user to define the operating point and operating zone for any machine, using the Pressure (P)-Flow Rate(Q)² graph. This information is linked to ProCAST’s solver to achieve virtual piston control in real time. Enabling a user to set-up parameters just as on the real machine, this enhancement provides a considerable time gain for process-design, and delivers the possibility to run a virtual benchmark and select the appropriate machine for specific jobs.

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