Analyze every phase of production with specialized modules. From mold preparation through solidification to final cutting operations, predict and prevent defects across your entire casting workflow.
Conversion of the CAD model into a 3D finite element mesh with mesh editing and automatic correction tools.
Preparation of the model for subsequent calculations: material database, initial calculation settings, boundary conditions, and process templates.
Handles radiation heat transfer, including re-radiation and shading, for vacuum and investment casting.
Mold filling, misrun detection, velocity and temperature analysis, hydrostatic pressure and feeding system verification.
Solidification dynamics, temperature-phase field calculation, hot spot identification, shrinkage cavities, macro/micro-porosity.
Residual stress and strain distribution, casting warping, and potential locations of cold and hot cracks.
Visualization and analysis of calculation results. Enables viewing of all calculation fields at any stage and any location within the casting.
Diagrams and charts from calculation results. Custom charts using formulas.
Criteria analysis for properties such as structure, hardness, slag, and mold wear. Includes customizable analysis functions like gradients and min/max value search.
A successful casting simulation requires balancing mesh precision with computational speed. The MESH module allows you to set higher mesh density only where critical detail is essential and coarser elements elsewhere, significantly reducing calculation times.
Import IGES, STEP and STL files
Automatic detection of conjugated surfaces
Geometry repair and gap closing tools
Global or local element-size control
Built-in mesh-quality optimisation
Tetrahedral, prismatic and hybrid meshes
High level of automation
No "manual" mesh editing required
Quality checks compare each element against simulation criteria such as aspect ratio, minimum angles and maximum edge length. Elements that fail these limits are fixed automatically without rebuilding the mesh.
Thin wall analysis pinpoints slender regions and adds local refinement to capture details and maintain solver accuracy.
When simulating casting processes, engineers often need to repeatedly calculate variations of gating systems, riser sizes or pouring temperatures, while thermal and material parameters remain unchanged. The MASTER module reduces repetitive setup tasks by allowing users to save frequently used settings as templates and apply them directly to any finite-element mesh.
Import finite-element meshes from ANSYS, NASTRAN, NX, SolidWorks, FEMAP, HyperMesh, Visual Environment and other CAE tools
Process templates that combine materials, boundary conditions and thermal profiles for each casting technology
Automatic inheritance of calculation settings when copying or modifying models
Editable material databases for alloys, mold sands, ceramics, insulating and exothermic sleeves
The Ceramic Mold Generator creates a finite-element shell mesh directly from the wax pattern surface at a user-defined thickness, without any prior CAD construction.
The generated shell can represent covers, refractory coatings, insulating or exothermic layers and is saved in a format ready for filling and thermal analyses.
PoligonSoft includes an editable library of metallic alloys and mold materials that supplies temperature-dependent properties to every simulation.
The database lists steels, cast irons, aluminum, nickel, titanium, copper, zinc and precious alloys together with sands, ceramic slurries, insulating mixes and exothermic sleeves, and users can add or modify records as required.
The Fourier thermal solver computes transient temperature and phase fields while accounting for conduction, convection, radiation and latent heat release during solidification.
It supports multi-stage analyses in which cooling conditions or geometry can change during the run.
The module makes it possible to calculate:
how temperature fields develop in the casting and the mold
how and when the casting solidifies
where hot spots form and why they appear
the shape, size and position of shrinkage cavities
the size and position of macro- and microporosity zones
One of the most notable advantages of PoligonSoft is its shrinkage macro- and microporosity model, which enables accurate prediction of defect formation in critical castings such as turbine and nozzle blades, monoblock wheels and pump impellers.
Specialized algorithms that account for capillary effects and pressure drops during the solidification of isolated hot spots further improve the accuracy of defect-pattern calculations.
PoligonSoft solves complex radiation heat-transfer problems, taking into account re-radiation and shading.
This capability is important not only for vacuum casting but also for casting foundry blocks on “trees” by investment-casting technology without a supporting filler.
The arrangement of castings on the tree and their relative positions during pouring and cooling can strongly influence the porosity pattern.
Internal chillers are inserts made from the same alloy as the casting and placed inside the mold cavity. During filling they partially or completely melt and fuse with the base metal, altering the thermal profile of the casting, its solidification, and helping to prevent shrinkage porosity.
The ability to model this process is a feature that distinguishes PoligonSoft from many other systems.
The Euler module predicts how molten metal enters and fills a mold at constant or variable speed.
It tracks the temperature drop that occurs when the metal touches the mold walls, quantifies heat transfer to the surroundings, and detects early solidification that can stop flow and create feeding defects.
A dedicated algorithm analyses the sprue system, pinpoints its critical locations and helps choose the best size, position and number of sprues and risers.
Temperature fields in the metal and the mold during filling
Velocity fields of the molten metal
Evolution of the free surface of the melt
Onset and progress of solidification during filling
Stopping criteria that indicate potential misruns
By combining a finite-element approach with adaptive element sizing, PoligonSoft can analyse castings that measure several metres yet include walls only a few millimetres thick.
The solver uses model symmetry and multithreaded computation to keep runtimes practical for very large geometries. Memory demand remains within the capacity of a standard office workstation, so no specialised HPC hardware is required.
The Hooke solver calculates the stresses and strains that arise as a casting cools and interacts with the mold. Its crack-prediction criterion highlights zones where cold or hot cracks may develop.
The same algorithms are applied to quenching, annealing and tempering runs, giving reliable estimates of residual stress, distortion and possible failure in both the casting and the mold.
Based on small elastoplastic deformation theory (A. Ilyushin) and a Newton iteration scheme, the module reports:
Magnitude and distribution of residual stresses
Magnitude and distribution of strains
Overall and axis-specific warping of the casting
Likely locations of cold and hot crack formation
PoligonSoft includes specific models for analyzing mold filling and shrinkage porosity in centrifugal casting.
The user specifies the axis, direction, and speed of the mold's rotation.
Combined with the ability to simulate investment casting, it is an indispensable tool for the production of titanium alloy castings.
Details
PoligonSoft allows for the calculation of continuous casting.
It simulates the conditions of pre-start retention and traction with cooling of the metal in the crystallizer, in the cooling medium below the crystallizer, and then in the air.
The module enables the investigation of the influence of various technological parameters on the quality of the casting and the occurrence of defective parts.
Details
Special module for the analysis of heat treatments in steels: quenching, normalizing, annealing, and tempering.
As a result of the analysis, the following is obtained:
Structure (martensite, bainite, ferrite-pearlite mixture)
Vickers Hardness
Yield Strength
Tensile Strength
Relative Elongation
Details
The solver models the formation of the grain structure during the cooling of molten metal.
The solver takes into account the chemical composition, the degree of supercooling, and the number of nuclei on both the surfaces and within the volume of the molten metal.
The result shows the quantity, size, shape, and spatial orientation of the grains.
DetailsThe program is designed to visualize three-dimensional dynamic fields of scalar quantities (for example, time-varying temperature-phase fields), previously simulated in the processor modules of the PoligonSoft system.
Users can interact with the visualized data, adjusting parameters such as transparency, isosurface representation, and viewing features like shrinkage cavities and flow patterns.
A graphical visualization module that allows users to visualize curves or graphs that have been prepared in the "Mirage" module.
It allows loading up to ten graphs simultaneously, each with its own color indicator for easy identification in the coordinate field.
Additionally, it offers the option to construct new graphs from a formula provided by the user.
A criteria analysis module for the obtained results.
Properties and parameters such as structure, hardness, slag, mold wear, cooling rate, among others, can be calculated and analyzed.
The module includes a wide range of integrated functions that allow the user to create custom analysis criteria suited to the specific needs of their production, such as powers, logarithms, trigonometric functions, gradients, rates of change, searching for minimum and maximum values, and others.
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