ESI GROUP, a developer of virtual prototyping software and services for manufacturing, released a new version of its metalcasting simulation software ESI ProCAST: it allows foundries and diecasters to predict manufacturing defects early and without the need for costly test runs or physical prototypes. As such, they can correct part design and manufacturing processes in advance of production, lowering scrap rates and delivering quality parts with consistency.

ProCAST 2016 promises even quicker turnaround times with new workflows dedicated to gravity casting and high-pressure diecasting. Set-up time for gravity casting — the most common sand casting process — is reduced to just a few minutes, while the workflow for high-pressure diecasting incorporates machine selection, and bridges the gap between design and production to increase efficiency on the shop floor.

Casting simulation helps industrial manufacturers and foundries comply with new and increasingly stringent market expectations and achieve the highest possible quality standards and productivity rates. To that end, ESI ProCAST provides a complete solution, covering all casting processes and the alloys used in diverse industry sectors, and the latest 2016 version focuses on key industrial challenges specifically related to sand, investment and diecasting processes in automotive, aerospace and heavy industrial production.

In regard to sand casting processes, ESI ProCAST 2016 includes a dedicated workflow for gravity casting, enabling simulation set-up within minutes. Taking all process parameters into account to deliver highly precise results, this step-by-step approach can be customized to fit any foundry's specific requirements and processes, delivering improved usability when repeating tasks.

The new functionality is easy to use and can be mastered by any operator within a few days.

Another notable enhancement to ESI ProCAST 2016 is the introduction of the machine selection workflow that draws on a dedicated database for high-pressure diecasting (HPDC) machines. The new functionality enables the user to define the operating point and operating zone for any machine, using the Pressure (P)-Flow Rate(Q)² graph. This information is linked to ProCAST's solver to achieve virtual piston control in real time. Enabling a user to set-up parameters just as on the actual machine, this enhancement provides a considerable time gain for process-design, and delivers the possibility to run a virtual benchmark and select the appropriate machine for specific jobs.