Frequently Asked Questions





What is simulation software?

Simulation software is based on the process of imitating a real phenomenon with a set of mathematical formulas.
It is, essentially, a program that allows the user to observe an operation through simulation without actually performing that operation.

Simulation software is used widely to design equipment so that the final product will be as close to design specs as possible without expensive in process modification.




Why Simulation?

Higher quality, efficiency, and process improvement always are target. You can use any tools to achieve these goals, Using the simulation has more benefit like:


Cost: Experiment in real life is costly and sometimes includes hiring more people and investing, besides this usually comes with the stopping production line to doing these experiences.


Time: With simulation you can run many times into the computer to get the result. So you can get the answer very quick as compared to do the test in a production line.


Repeatability: It’s really difficult to repeat the exact conditions again and most of the times you can't test different ideas under the exact same circumstances. Guessing which idea is really the best might be a big challenge. With simulation you can test the same system over and over again with different inputs.


What is casting simulation?

Casting simulation is a powerful tool to analyze and visualize casting design during the mold filling and solidification.



What is SUTCAST?

SUTCAST is casting simulation software, SUTCAST’s ability to analyze every aspect of the metal casting process and convert it into a 3-D model. Software provides a more complete understanding of the process, and in turn, improves the quality of the end-product.


Which processes can be simulated with SUTCAST?

A number of processes can be simulated with SUTCAST, including sand casting, permanent mold casting, low pressure die casting, and investment casting. A new module for high pressure die casting will be added soon.




Which numerical method is used by SUTCAST?

SUTCAST uses Finite Difference Method (FDM) for three dimensional modeling of the casting process.


Does SUTCAST support older versions?

Yes. SUTCAST is designed so that all older versions of the program are supported. Data from older versions are converted to formats used by the latest version automatically.


Which file types are supported in SUTCAST?

Solids are imported as STL files. S3D, DATA, and MDB files are generated in pre-processing module of SUTCAST. Output files come in SUT, VEC, PLT, HB, UTS, YS, VOL, and MOD.


What is a STL file?

The STL or stereo lithography format is an ASCII or binary file used in manufacturing. It is a list of the triangular surfaces that describe a computer generated solid model. This is the standard input for most rapid prototyping machines. 


What is the suggested hardware requirement for the running SUTCAST software?

Windows XP professional
Core 2 Duo or Dual Core Processor
250 GB Hard Disk space

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    Does SUTCAST use separate software for mesh generation?

    No. Mesh generation is performed by SUTCAST pre-processing module. 


    Is there any limitation in number of meshes?

    Generally no. Millions of meshes can be used for meshing the object. However, a minimum number of three meshes are required for the thinnest section of the part.


    Which metals/alloys can be modeled?

    SUTCAST benefits from a large database for metals and alloys including carbon steels, alloy steels, gray iron, Al-base alloys, Ni-Cr alloys, Ni-Co alloys, Tin-Bronzes, Brass, Al-Bronzes, Ductile iron, Chromium steels, Malleable iron, Magnesium alloys, and Zinc alloys.


    What about other materials?

    The database is a flexible one, so that users can add new materials to be modeled.


    Does SUTCAST model mold materials?

    Yes. Properties of various mold materials are included in SUTCAST 


    Which objects are included in modeling?

    Exotherms, chills, and different types of sands are also included and can be used in modeling. Moreover, there is a possibility of adding new objects to the system through defining their properties.


    Is it possible to track the fluid flow inside a mold?

      Yes. SUTCAST provides an animated output for the fluid to flow. 
    A temperature profile (of the fluid) is also provided by SUTCAST.


    What other features are included in fluid flow module?

    Velocity and pressure distribution inside the molten metal are visualized by SUTCAST.


    Is it possible to locate the position of defects in a casting?

    Yes. Both micro- and macro-shrinkage can be modeled with SUTCAST. Also, it is possible to find the position of the molten metal in the last steps of solidification (liquid mapping).


    What’s new in SUTCAST version 9.1?

    • Variable mesh size
    • Faster algorithms to reduce simulation time
    • Modeling objects up to 25,000,000 computational cells
    • New parameters and results such as, Thermal gradient, Local solidification times, Hot rearing, Liquid Fraction
    • Multiple particle tracking
    • Thermal contact resistance between objects
    • simulation report  
    • More tools and option for visualizing STL objects
    • New interface with advanced feature for solidification
    • Visualization
    • Generation of static images as well as video files from standard and custom-defined sections
    • Small file size to save space
    • Multiple cooling curves
    • Variable velocity of pressure boundary condition
    • Precise algorithms for macro shrinkage prediction


    Why SUTCAST?

    SUTCAST is the most powerful simulation software professionally designed for the modeling of casting process.
    For a quarter century experience back in 1984, SUTCAST group has been developing many advanced algorithms making it possible to predict the performance of casting systems in the most accurate way and more rapid than ever.

    SUTCAST is developed by a group of experts specialized in foundry engineering, mechanical engineering, metallurgical engineering, software engineering and metal caster who like to share their skills, knowledge and experience with both industrials and researchers to provide a trustable software.
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