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Three main improvements have been made for the new version. ProCAST 2006 can now predict porosity by taking into account the phenomenon of graphite expansion in nodular cast iron. In this specific material, the formation of graphite nodules during solidification leads to a volume expansion. The capacity of ProCAST 2006 to couple local microstructure calculations with porosity predictions is a real benefit for the cast iron industry.
Secondly, with the delivery of ProCAST 2006, important progress has been made – the meshing time for models that previously took hours to mesh now only takes minutes with the new version. This improvement is also due to the use of Geomesh, the ESI Group tool for geometry analysis and repair, whose interface allows the use of major industrial native CAD file formats.
Finally, parallel processing of mould filling and solidification had already been included in the previous ProCAST release. With this new ProCAST 2006 version, the stress module is fully parallelised, allowing the complete casting process to be simulated in hours.
Casting process simulation is now widely accepted as an important tool in product design and process development to improve casting yield and quality. ESI Group’s casting portfolio includes ProCAST, the market-leading finite element solution for casting process simulation; CALCOSOFT, for fast and efficient modeling of continuous casting processes; and PAM-QUIKCAST, the finite difference solution for casting process evaluation. ProCAST 2005 has received the European Technology Leadership of the Year Award from Frost & Sullivan.