CastCAE Introduction >> Simulation Basics >> Modeling the Geometry >> Mesh Generation >> Validation >> Customer Comments >> Hardware Requirements >> Benefits
Simulation Basics
CastCAE simulates
  • mould filling
  • solidification
  • iron properties
  • casting defects

Physical models used:

Control Volume Method, Navier-Stokes equations, viscosity, surface tension, temperature field, density, thermal conductivity, specific heat, latent heat, transformation heats, cooling rate, cooling time, heat transfer coefficients, coatings, combustion heat, combustion rate, hardness, nodule count. All properties are temperature-dependent.

All types of foundry equipment, like chills, insulating and exothermic sleeves, investment and Replicast® shells, sands, etc. can be incorporated in the model and calculations. Coatings can be applied to components and selected surfaces separately.

CastCAE can be used for
  • steel
  • iron
  • light alloys
  • copper alloys
  • superalloys
  • precious metals


  • sand casting
  • Replicast®
  • investment casting
  • Croning process
  • gravity die casting
  • low-pressure die casting
  • high-pressure die casting

Because of the rectangular mesh and Control Volume method (an extension of the Finite Difference Method), the results are reliable even with rough meshes and so are suitable for everyday use of simulation in the design process. You can make several simulations in just a few hours. CastCAE simulation results are constantly verified against reality to ensure good agreement with real situations.



CastCAE shows the simulation results as AVI or QuickTimeTM - animations and as X-ray models. Time-animation (right) shows the progress of the filling or solidification as a function of time. Tomographs allow the user to slice through the component and see the temperatures and defects layer by layer. Criterion functions show the calculated values of each criterion function, layer by layer.

Animations are created on-line and can be viewed also during the simulation's progress. Any number of simulations can be initialized to run successively.

X-ray model is a unique way to view the defects. User can rotate and zoom the model with the defects in 3D. It is the ideal way to send the results to the customer or to the inspection department.


CastCAE comes with a wide, built-in database of materials. Material properties can also be added to the database. For steels, bronzes, aluminiums etc., properties taken from literature or other measurements can be used accurately. CASTech provides iron foundries with a set of simple test procedures to tune up the calculated material properties. With irons this is very important, because the treatments change the expansion and shrinkage characteristics of the irons dramatically and thus have to be taken into account. The database also includes properties for most popular sands, insulating and exothermic sleeves, etc.


CastCAE Introduction >> Simulation Basics >> Modeling the Geometry >> Mesh Generation >> Validation >> Customer Comments >> Hardware Requirements >> Benefits


Updated 06.08.00