Adstefan
Casting Manufacturing

About Aganita:

We provide casting simulation services and solutions. We use state of art - casting simulation software, ADSTEFAN from Hitachi to help foundries in India and overseas.

Our founder and promoter bring more than 40 years of experience in casting simulation, modelling, and finite element analysis. We pioneered the casting simulation in India in late 1990s through ProSIM. Now Aganita has been formed to service casters and foundries in India exclusively.

We empower foundries and casting companies to gate optimization and process parameter optimization, enhance productivity, reduce rejections, casting yield increase and deliver superior quality castings.

Utilizing a physics-based approach, we employ cutting-edge metal casting simulation techniques. We use casting solidification simulation software to simulate the flow of molten metal in die and mold cavity. We further simulate and predict the heat transfer in the molten metal as well as in die and mold.

Using this sophisticated technique, we work to determine casting defects before physical trials. This includes shrinkage porosity prediction, air entrapment prediction, prediction of blow holes, hot tears, cold shuts, Casting crack prediction, Casting warpage prediction, and misruns.

Over the years, we have partnered with several hundreds of casting companies and foundries in India and abroad, delivering tangible results in terms of casting rejection reduction, casting yield improvement, and improve productivity.

Using our expertise in casting defect analysis and casting melt flow simulation, our clients have got benefitted to increase their profitability and productivity.

Our casting methods simulation and accurate casting defect prediction-based engineering solutions offer a comprehensive approach to addressing the challenges faced by the casting industry.

For your problems associated with casting defects and remedies contact us.

vision

To be a global leader in Engineering Design and R&D solutions

Values

Integrity, service excellence and teamwork

Aganita Competency

Casting Manufacturing

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Casting Manufacturing

Casting Manufacturing

This is needed for existing castings that have unusually high or unexpectedly varying level of internal defects

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Casting Troubleshooting

Casting Troubleshooting

This is needed for existing castings that have unusually high or unexpectedly varying level of internal defects

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FAQ's

  • What is casting simulation?
  • Casting simulation is a process that uses computer software to model the behavior of molten metal as it is poured into a mold and solidifies. This helps predict and mitigate potential defects in the final cast product.
  • Why is casting simulation important?
  • Casting simulation helps manufacturers optimize the casting process, reduce defects, improve quality, and save costs by predicting issues such as shrinkage, porosity, and incomplete filling before actual production.
  • Which industries benefit from casting simulation?
  • Industries such as automotive, aerospace, construction, and any sector that requires high-quality metal components benefit from casting simulation. It is particularly valuable in sectors where precision and reliability are critical.
  • What software is commonly used for casting simulation?
  • Some commonly used casting simulation software includes ADSTEFAN, MAGMASOFT, ProCAST, FLOW-3D CAST, AnyCasting, and Simufact. These tools offer various features for different types of casting processes and materials.
  • How accurate are casting simulations?
  • The accuracy of casting simulations depends on the quality of input data, including material properties, process parameters, and the resolution of the mesh. Advanced software with precise data can achieve high accuracy, closely matching real-world results.
  • Which software can perform air entrapment simulation?
  • ADSTEFAN casting simulation software can perform air entrapment simulation and perform air entrapment prediction by visualizing air pocket isolation during flow of molten metal inside mold cavity. Through this we can also determine placement of air vents to evacuate isolated air pockets inside cavity.
  • What are common Casting defects and remedies?
  • Common casting defects include Gas porosity (caused by gas entrapment), shrinkage porosity (due to insufficient material), cold shuts (poor fusion of molten metal), and misruns (incomplete filling of the mold cavity). Remedies involve proper gating and riser design, controlling pouring temperature, ensuring adequate venting. Through using casting simulation software tool we can virtually analyze and understand casting defects and remedies by shrinkage porosity prediction, air entrapment prediction, Casting porosity prediction
  • Can we optimize casting methoding using casting simulation software?
  • Yes. casting simulation software such as ADSTEFAN can be used for casting methoding optimization. We can perform virtual trials for different methoding concepts and choose best concept with lesser defect probability considering casting yield enhancement.
  • How casting simulation software help to regulate casting rejection?
  • Yes, using casting defect prediction simulation software like ADSTEFAN we can understand root cause for casting defects such as shrinkage porosity prediction, air entrapment prediction, Cold shut, Inclusion, crack defects and take preventive actions before actual production thus regulating casting rejections.
  • What are the key parameters needed for casting simulation?
  • Key parameters include material properties (thermal conductivity, specific heat, density, viscosity), mold geometry, pouring temperature, flow rate, cooling conditions, and environmental conditions.
  • Can casting simulation predict all types of defects?
  • While casting simulation can predict many types of defects, including shrinkage, porosity, and cold shuts, it may not capture all possible issues, especially those related to microstructural changes or unforeseen process variations.
  • How does casting simulation help in design optimization?
  • Casting simulation helps in design optimization by allowing engineers to experiment with different mold designs, gating systems, and process parameters virtually. This reduces the need for physical prototypes, saving time and resources.
  • What are the limitations of casting simulation?
  • Limitations of casting simulation include the reliance on accurate input data, computational costs, and the complexity of accurately modeling all physical phenomena involved in casting. Additionally, simulations may not account for all real-world variables.
  • How does one validate a casting simulation?
  • Validation of casting simulations involves comparing the simulation results with experimental data from actual castings. This can include dimensional checks, defect analysis, and mechanical property testing to ensure the simulation accurately reflects reality.
  • How can we do casting rejection elimination in foundry?
  • Casting rejection elimination can be done by following controlled casting process parameters and gating design validation by computer simulation and gating optimization. Process parameters optimization is done well before actual production trials by using casting defect prediction and validation casting simulation software such as ADSTEFAN.
  • Can Gating optimization for castings be done using casting simulation software?
  • Yes, gating optimization can be done using ADSTEFAN casting simulation software. We can optimize gating design and run iterations based on virtual trials to finalise best gating design.
  • What are uses of metal melting simulation?
  • Metal melting simulation or metal casting simulation using software such as ADSTEFAN is used for conducting virtual trials and predicting possible casting defects such as shrinkage porosity, gas porosity, cold shut, cracks, warpage, inclusion. We can also perform gating optimization and process parameters optimization to achieve good sound casting in first shop floor trial itself saving Product lead time, cost, manpower and energy.
  • Can Thermal balancing die casting be done using virtual casting simulation software?
  • Yes, modern metal casting simulation software such as ADSTEFAN casting simulation software can perform thermal balancing die casting. Using computer simulation of die casting, temperature distribution in the dies during melt filling of die cavity and during solidification can be predicted. Using this, engineer can understand how to position and design cooling lines and effect of cooling lines. Engineer can also understand number of shots required for the dies to reach stable steady state temperature.

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