Procast CAE simulation is the core digital design tool for casting molds, with standardized core parameters ensuring simulation accuracy and guiding mold structural optimization.
Conventional LPDC mold simulation adopts 800,000+ grid units, while CPC high-pressure molds require 1 million+ high-precision grid division.
Simulation temperature field range is set at 620–720℃, covering the full working temperature range of aluminum alloy casting production.
Filling velocity simulation parameters are matched by process: LPDC 0.8–1.2m/s, gravity 0.4–0.6m/s, CPC 1.0–1.5m/s.
Solidification time simulation error is strictly controlled within 4%, ensuring consistent matching with actual mold trial-test data.
Porosity shrinkage prediction module accurately simulates defect generation positions, reducing physical trial-test failure rate by 35%.
Temperature gradient simulation controls local temperature difference threshold, guiding cooling channel layout optimization for EV thin-wall molds.
Pressure field simulation exclusive for CPC molds verifies high-pressure sealing and feeding uniformity under 0.1–0.15MPa working pressure.
Aluminum wheel mold CAE simulation focuses on rim thickness difference and spoke solidification sequence balance optimization.
Simulation iteration optimization improves mold structural rationality, increasing final casting qualification rate by 4–6%.
Procast CAE simulation data is archived as official mold design documents, supporting customer technical verification and production debugging.
Digital CAE simulation replaces traditional empirical mold design, realizing precise and visualized development of aluminum casting molds. Standardized grid division, temperature field, velocity field and pressure field parameters ensure the accuracy of simulation results for different process molds. LPDC, gravity and CPC molds have independent parameter matching schemes according to their filling and solidification characteristics, avoiding one-size-fits-all simulation errors. The professional defect prediction module accurately locates potential porosity shrinkage, shrinkage cavity and gas trapping defects in advance, guiding targeted optimization of gating system, exhaust structure and cooling layout. For customized wheel molds and complex EV structural molds, CAE simulation solves personalized structural defect problems that traditional experience cannot predict. Multiple simulation iterations optimize mold parameters to the optimal state, greatly reducing the risk of mold modification after trial-test and shortening mold development cycle. Complete simulation data archiving provides reliable technical support for customer production debugging and quality certification.
FAQs
Q1: How many grid units are required for standard LPDC simulation? A1: No less than 800,000 grid units for basic simulation accuracy.
Q2: What grid standard applies to CPC high-pressure mold simulation? A2: 1 million+ high-precision grid units for high-pressure process simulation.
Q3: What filling velocity is simulated for gravity casting molds? A3: Stable velocity range 0.4–0.6m/s for natural filling.
Q4: What is the maximum allowable CAE simulation error? A4: Solidification and temperature field error strictly controlled within 4%.
Q5: How much does CAE simulation reduce trial-test failure rate? A5: Reduce physical mold trial failure risk by 35% effectively.
Q6: What simulation focus for aluminum wheel mold design? A6: Rim thickness difference and spoke solidification sequence balance.
Q7: How much yield improvement does CAE optimization achieve? A7: Increase final casting qualification rate by 4–6% stably.
