Simulation

Before the first drop of metal flows, we perfect the casting process virtually. Numerical simulation is an indispensable tool in modern foundry technology. By using state-of-the-art CAE systems, we can digitally predict and optimize mold filling, solidification, stresses, and warpage. This shortens development times, conserves resources, and ensures flawless component quality.

We use established industry software for the design and optimization of complex castings, as well as for calculating fluid flow and structural mechanics:

• MAGMASOFT® & Flow-3D: CFD software for comprehensive simulation of mold filling, solidification behavior, and residual stresses in the casting process.
• SIGMASOFT®: Virtual process optimization (including for thixomolding).
• Abaqus & Ansys: Powerful FEM (finite element method) software for complex structural mechanics and thermal calculations.
• OpenFOAM: Open-source CFD (Computational Fluid Dynamics) toolbox for detailed flow simulation.
• JMatPro: Software for calculating material properties and phase diagrams of metallic alloys.

Our students and researchers have access to powerful CAD systems for the tool-optimized 3D design of components, casting runners, and permanent molds:

• CATIA V5
• Siemens NX
• Creo Pro/ENGINEER
• SolidWorks

For the automation of test benches and professional measurement data acquisition, we use:

• LabVIEW: A visual programming environment for complex measurement, control, and regulation applications.
• catman: Software for data acquisition and analysis in conjunction with our test stands.

To ensure that our students and research staff have access to our software infrastructure at all times, we have two fully equipped computer labs with identical software packages:

• Metakushalle Computer Lab (Research & Technical Center)
• Computer Lab at the Holländischer Platz Campus (HoPla)