Engineer pouring metal casting parts from ladle in foundry specialized in sand casting simulation.

Here's Why You Need Sand Casting Simulation


Nov 4, 2022

Sand casting is an area of manufacturing with a historical vulnerability to numerous quality defects. Problem-solving efforts often resembled art more than science, with trial-and-error efforts to correct tooling and processes. In the casting industry, a foundry engineer must consider a myriad of variables that impact the final product. 

Producing quality parts can be challenging, with many elements to consider and balance. Still, these problems can be avoided if the design is tested and optimized before the product is put into production. Sand casting simulation software serves as the solution.

A Sand Casting Simulation Solution: THERCAST®

A sand casting simulation can predict the microstructure, part defects, and solidification and guide you through process optimization. This allows the designer to assess the potential defects that may occur in the design and then eliminate them before making tooling and thus avoid costly repairs.

THERCAST® by Transvalor Americas is one example of 3-D simulation software that offers an answer. This software is an invaluable virtual engineering resource that allows the designer to visualize the flow of molten metal into the mold and how it will solidify. The simulation is a transient thermal analysis performed with highly specialized 3-D software. 

The sand casting simulation models the heat distribution during the solidification process and isolates problem areas. Thermal distribution within the mold and cast part is critical for overall casting quality. The resulting thermal data from the simulation is essential to optimize the design of the delivery system, venting, and process parameters. 

The design headaches with gates, runners, vents, and risers are a thing of the past. The software also has the flexibility to tune the product and process to deliver optimal performance, quality, and yield. 

Predict and Eliminate Potential Defects 

  • Blow Holes 
  • Cold Shuts 
  • Distortion 
  • Contraction 
  • Cracking
  • Splitting
  • Grain Structure 
  • Hard Spots 
  • Hot Spots
  • Shadowing 
  • Porosity 
  • Shrinkage 
  • Polycrystal Deformation
  • Predict the microstructure of the final product 
  • Determine the final in-use part properties, such as hardness and residual stresses 

Once the 3-D design is finalized, the process parameters can be quickly loaded unto the production floor. Simulation software takes the process of optimizing complex castings from weeks or months down to mere hours.

By avoiding this wasted time, you prevent scrap production, lost production time, and the time to market is expedited. Your foundry engineers also spend more time on new product design than troubleshooting. Simulations can also help improve casting quality, reduce development costs, and speed up production optimization.

THERCAST® 3-D Simulation Software Capabilities:

Listed below are some of the many capabilities of THERCAST® by Transvalor Americas:

Validate Mold Design 

Predict & Eliminate Defects 

Fine Tune Process Variables 

Design Optimal Runner & Sprue

Expedited Design Time

No Tooling Changes

Optimum Gate Design

Proper Die Coating

Simulate Complex Geometrics 

Model Laminar Flow

Evaluate Thermal Gradient

Predict Microstructure

Predict Hot Points

Impact of Shadowing 

Alloy Selection

Compression Strength

Pouring Rate

Pouring Time & Temperature 

Advantages of THERCAST®  3-D Simulation Software:

Manufacturing researchers have studied the manufacturing process from concept to finished production parts. They have determined that approximately 90% of the defects in production parts are due to errors in the design. A manufacturing rule of thumb states that the cost to change in design increases tenfold for every step of the design and manufacturing process, which helps to illustrate further the advantages of metal casting software

Aside from the software benefits, there are several other benefits, most of which are easily measurable to justify the software quickly. Transvalor Americas sand casting simulation software is an excellent investment.

Benefits of THERCAST® 3-D Simulation Software

  • Accurate job cost and quotations 
  • Improve competitiveness 
  • Increase market share 
  • Improve product quality 
  • Increase return on investment (ROI) 
  • No lengthy prototyping 
  • Optimized process parameters 
  • Reduce design phase costs 
  • Reduce lead times 
  • Reduce process scrap 
  • Reduce production time and costs 
  • Reduce prototyping costs 
  • Reduce tooling costs 
  • Reduce time to market 
  • Time savings for engineers

Advantages of THERCAST®  3-D Simulation Software:

THERCAST® is the benchmark in metal casting software and is ideal for sand casting simulation and design. It is a 3-D software solution that simulates the casting process and refines tooling design. The software can predict the microstructure, part defects, and solidification and guide you through process optimization. 

It will remove the headaches from sand casting simulation and design with the field's most advanced, intuitive, and easily customizable user interface. The problem solver built into THERCAST® is advanced, intuitive, and the best in the field. Transvalor Americas team also has the business's best online problem-solving support team.

Our software is designed to help manufacturing companies reduce production costs, shorten time to market, and accelerate product delivery. Transvalor Americas also offers advanced sand casting simulation services for your casting projects. Consulting is available, as is onsite and online training. We will do whatever it takes to get your team up and running quickly.

THERCAST® is one of several of our metal casting software solutions, including hot forging, cold-forming, predicting welding defects, heat treatment, and microstructure analysis. If you would like to see how much you can save before committing to THERCAST®, contact Transvalor Americas.

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