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Since its first release in 2008, STAR-Cast has been a game changer in the sand casting industry. From small, thin-walled aluminum castings to large cast iron parts weighing several tons, STAR-Cast can help optimize all common sand casting processes. Drawing on the strength of its two parent companies, Access e.V. and CD-adapco, STAR-Cast is an efficient and accurate computational software tool that allows the simulation of sand casting processes with very high precision.
STAR-Cast is applicable to all sand casting processes, including:
• Gravity sand casting • Low pressure sand casting • Roll-over sand casting
The multiphase approach allows entrapped air to be tracked throughout the casting system, highlighting insufficient venting of the mold or oxide entrainment in aluminum castings.
Gas flow through porous mold: Of special interest to sand casting is the dissipation of air through the porous sand mold during filling and solidification. STAR-Cast allows the user to define the mold as a porous region, and to visualize the escape of gases through the sand.
Sand wash prediction: Computing wall forces and pressures accurately permits a reliable prediction of eroding effects in sand molds.
Highly precise, locally refined meshes are crucial when simulating sand casting processes. STAR-Cast features automatically created, body-fitted, polyhedral meshes with prismatic layers to accurately capture the flow behavior and strong temperature gradients.
Meshed model of a casting flask, including the drag, casting and chills
Streamlines and velocity magnitude on the surface of the melt during the filling process
Temperature distribution in a sand mold after complete filling
ResellersAustraliaCD-adapco [email protected]
Israel ADCOM Consulting Services (Shmulik Keidar Ltd.)[email protected]
New ZealandMatrix Applied Computing [email protected]
RussiaSAROV Engineering [email protected]
South AfricaAerotherm Computational [email protected]
TurkeyA-Ztech [email protected]
Corporate HeadquartersCD-adapco60 Broadhollow RoadMelville, NY 11747USA
+1 631 549 [email protected]
Americas Austin • Cincinnati • Detroit • Houston • Los Angeles • New Hampshire • Orlando • São Paulo • Seattle State College • Tulsa
Europe Glasgow • London • Lyon • Madrid • Nuremberg • Paris • Prague • Rome • Toulouse • Turin • Vienna
Asia-Pacifi cBangalore • Beijing • Busan • Chennai • Pune • Seoul • Shanghai • Shin-Osaka • Shin-Yokohama • Singapore
Crucible tilting, mold withdrawal, roll-over processes and other body movements can be simulated with the STAR-Cast overset mesh technology. All motions applied to the system can be combined in one simulation, resulting in a realistic representation of the complete casting process.
Prediction of misruns and cold shuts is of great importance for thin-walled sand casting geometries. To capture these filling-related defects, STAR-Cast simulates the solidification of the melt using a fine mesh around the filling front, and the dedicated slurry, mushy zone, and flow stop models, which reduce the melt flow until complete stop.
Micro-structure and porosity analyses are based on dedicated criteria functions evaluated throughout the simulation. Macro-shrinkage prediction, solidification condition (G/v), dendrite arm spacing, and micro-porosity indication are accessible at all times of the simulation. After the filling, STAR-Cast can analyze the solidification based on either a fast thermal-only analysis or on a more precise calculation including convection.
Oxide inclusions prevention in aluminium castings: Reflecting melt fronts with plunging waves are a source of oxides. In order to accurately predict air entrapments and the resulting oxide film inclusions, the melt front needs to be tracked with precision. STAR-Cast monitors the duration of the melt’s contact with air as a passive scalar and calculates the final distribution of those oxide entrainments.
Simulation of crucible tilting to predict precise mold filling conditions
Misrun prediction in aluminium casting
Melt wave rolling back in an oversize runner
Prediction of oxide entrainments
