Consider a hypothetical—but realistic—scenario in the production of a large automotive suspension knuckle. These parts are complex, with thick bosses connected to thin webs.
In a traditional workflow, the part is cast, and a crack is discovered in the web area during machining. The engineers change the gate location, hoping to alter the thermal profile. They re-run the tool, scrap thousands of dollars in metal, and the crack moves to a different location. i--- Flow 3d Cast Advanced Crack
Using FLOW-3D CAST Advanced, the engineer simulates the process and observes a stress concentration at the junction of the boss and the web. The software reveals that the core is cooling faster than the surrounding metal, creating a "pulling" force. The simulation suggests that altering the cooling channel layout to homogenize the temperature—or adding a fillet to reduce the stress concentration—will alleviate the load. The virtual prototype confirms the fix before a single piece of steel is cut for the tool. CSR (Critical Strain Rate) Model – User-calibrated
Flow Science offers daily, weekly, or monthly rentals. Need to run a single critical HPDC simulation? Rent a license for $500/week instead of paying $40k upfront. Elastic-Plastic Stress Criterion – For cold cracks
CSR (Critical Strain Rate) Model – User-calibrated.
Elastic-Plastic Stress Criterion – For cold cracks.
Students and professors can obtain heavily discounted (or free) licenses for educational use. The solver is time-limited (e.g., 6 months) but fully functional. No cracks, no malware.