Every zinc die caster knows that in HPDC the metal entering into the cavity is like a gunshot. Liquid metals flows in the die in a very turbulent way, with a stream velocity of more than 40m/s and in a few milliseconds clogs die vents, entraps the remaining gas, fills up the cavity and starts to solidify.

At those speed rate the metal doesn’t present an united flow front but it is crushed in many minute droplets which are composed of both metal and air. What is filling up the die is not simply an alloy but an emulsion of metal and air which has proprieties (viscosity, density etc) different from the metal itself. The simulation software are expected to help the die casters to reduce air entrapment during the filling. But in the most common commercial packages, air is merely “the space not filled by metal” and the effect of air on fluid flow is not considered at all: in a single phase the mesh cell can be either full or empty but never filled by a mixture of both metal and air. The accuracy level of air entrapment prediction is therefore limited by the mesh size defined by the software and the flow front is supposed to be usually smoother than the actual “spray effect” front.

Castle is a dual phase simulator: it calculates the combined action of a liquid (the metal) and a gas (the air), one uncompressible and the other compressible with very different densities. Providing extremely accurate results the system evaluates the effect of the metal spraying and incorporates analysis of the physical effects of both vacuum and vents. Additionally it considers the actual zinc rheology that is the real behaviour of the alloy that solidifies and changes its viscosity in a very narrow temperature range and it is very important especially for zinc thin parts. Also zinc/mould and zinc/air surface tensions and surface wetting are considered in filling dynamics. Zinc die casters dealing with too polished dies well knows the «sticking effect» of this kind of surfaces.


-Full 3D CAD capabilities

-Model preparation and setup for the calculation in under a minute

-Multiprocessing and cloud computing compatible

-Dual Phase simulation: metal pulverization, spray effect and micro air entrapments detected.

-Vacuum and vent effects calculation

-Interactive practical suggestions


Discover your suitable solution package

-Hybrid Mesh Approach > read more

-Process Optimization > read more

-Fast Runners simulation > read more

-Filling and solidification analyses > read more


Hardware suggestions

CPU: Processor Intel® Xeon® E5-2609 v2 (quad-core HT, 2,5 GHz, 10 MB) RAM: 16 Gb DDR3 with ECC RDIMM a 1866MHz Graphic card: NVIDIA® Quadro® K2000 2 GB or similar (alternatively: NVidia GeForce GTX 670) HDD: 1TB 3.5inch (7200 RPM) SATA / Alternatively: 1 SSD da 128 Gb (OS + Programs) + HDD SATA 1Gb (Data)