Flow modeling provides a computer simulation of the metal flow within the die-cast die. This is where the molten hot zinc is pushed through the gooseneck and into the die cast (the mold that holds the shape of the part).
Brillcast does this using a software called FLOW-3D. FLOW-3D enables highly accurate simulations of free-surface flows using TruVOF, the original and true form of the Volume-of-Fluid technique. Above are pictures of what a FLOW-3D output looks like. The simulation points out any spots that may cause problems when pushing the zinc into the die.
These simulations take huge amounts of data and time. Depending on the part’s size and complexity, a flow simulation can take from 1 day to over a week to finish. In an age where computers seem to process faster than the speed of light, it’s hard to imagine how much information that really is, but it’s worth the wait in order to get it right the first time.
Running these flow simulations saves Brillcast time, frustration and money. They help determine flow issues early on and play a vital role in designing tools. It’s much cheaper to make changes to a design in a CAD model versus welding or cutting steel after the tool has been built. Along with saving money for Brillcast, running flow simulations saves customers money in tooling and engineering time.
If you have any questions about design capabilities or zinc’s potential, please don’t hesitate to contact Brillcast’s team. Reaching us by phone is quickest (616) 534-4977, but you can also email a question from our Contact page.