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Sand Cast
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1 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Advanced Casting Simulation Software
“ Any Service & Software will be
Casting to Customers ”
Software Introduction (Sand Casting)
TM
AnyCasting
2 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Total Analysis of All Casting System
▶ 3-D Mold Filling Porosity, shrinkage/Solidification, Mold
▶ 3-D Thermal Stress / Micro Structure / Mechanical Properties
Main Window of AnyCasting System (SAND) Main Window of AnyCasting System (HPDC)
Die
Chill Vent
Line Channels
Shot Sleeve
Runner
Slide Core Pins
Sprue
Drag
Core
Pins
Cavity
Cavity
TM AnyCasting
3 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Import & Assemble of 3D CAD/CAM Data
▶ UG, CATIA, I-DEAS, Pro/E, etc. ▶ CAD Operations (Merge/Boolean/etc.)
▶ Classify Parts : Product, Runner, Gates, Channels, O/F & A/V
CATIA
PRO Engineering Solidworks
UniGraphics
Import
Assembly Control of CAD Data
AnyCasting
User can use only STL format
4 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
HPDC/Thixo Module
LPDC Module
Permanent Mold (Tilt) Module
Sand Module
- Cast Iron
- Cast Steel
Large Ingot Module
Investment Module
Software Structure
System Configuration
AnyPRE
AnySOLVER
AnyPOST
AnyMESH
AnyDBASE
BatchRunner
anyTX
Advanced Material Properties
Cast Iron Module
Eject Pin Module
AnyCasting Extensible Module
AnyCasting Standard AnyCasting Performance
5 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Input Data Solving Observation
- Modeling File (STL)
- Meshing
- Set Casting Condition
- Using Multi Core Process
- Dramatic Decreased
Solving Time
Fluid
- Entrapped Air / Gas
- Oxide
- Temperature
- Velocity
- Leakage
Solidification
- Final Solidification Area
- Micro / Macro Shrinkage
SW Configuration
AnyCasting Work Flow
▶ Input Data & Solving & Observation
6 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
SW Configuration
AnyCasting Work Flow
▶ Input Data & Solving & Observation
Input Data
- Modeling File (STL)
- Meshing
- Set Casting Condition
- Meshing
- Set TEMP.
- Set HTC
- Set Pouring Temp.
- Set Shot Condition
- Set Channel
- Set Cycle Condition
7 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Solving
- Using Multi Core Process
- Dramatic Decreased
Solving Time
SW Configuration
AnyCasting Work Flow
▶ Input Data & Solving & Observation
8 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Observation
Fluid
- Entrapped Air / Gas
- Oxide
- Temperature
- Velocity
- Leakage
Solidification
- Final Solidification Area
- Micro / Macro Shrinkage
SW Configuration
AnyCasting Work Flow
▶ Input Data & Solving & Observation
Filling Sequence Temp.
Distribution
Core Gas
Cast Iron Module
- Tensile Strength
Melt Velocity
9 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Development Roadmap
V1.0
- Anycasting Release
V2.0
- Predicting Oxide - Shot Sleeve Setting - Vacuum Setting - Melt Supply Setting - Thermal Stress Analysis
V3.0
- Real Shape - Large Ingot - Centrifugal Casting - Chinese Version
V4.0
- Real Flow - Filter - Auto Report - Calculating Properties - Multi Language - Predicting Core Gas
V5.0
- Multi Process - Cast Iron - Predicting Eject-Pin Stability
V6.0
- Auto Mesh - Enhanced Centrifugal Casting - Quantitative Analysis - Result Combination - Predicting Gas Defect
- Enhanced Particle Tracing - Enhanced Channel HTC - Exothermic Sleeve - CPU Core Setting
V6.1
2001 2008 2012
2005 2010 2013
2014
10 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Moving Rotating
(Free Section)
Exact View by Dynamic Arbitrary Section
Observe Inside of All Entity Parts ▶ X, Y, Z 3 Direction Dynamic Moving Section View
▶ Detail Observation of STL Geometry & Calculation Result
AnyPRE Process AnyPOST Process AnyPOST Process
▶ Dynamic Arbitrary Section Function be Provided Continent Observation to User
▶ User can Check Inside of All Entity Parts Easily Where is Thin or Thick Area
11 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Fast Graphics & User Interface ▶ Fully 3D (Open GL 3D), Fast Algorithm: Surface Compiling Method
▶ Set All Conditions by Graphics User Interface
Set Material
by Mouse
Clicking
Automatic Gate Detecting, Set Gate Condition
Dynamic Section Viewing
Number of Mesh : 31 Mill.
Graphic Speed Acceleration
12 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Analysis of Geometry & Mesh
by 3-D Graphics in Pre-Processor
Fast Meshing Algorithm
Meshing Speed : 5 sec per 20 Mill. Mesh ▶ Surface Vector Tracking Method
▶ Intersected Polygon’s Normal Vector Analysis
STL Geometry Meshed State
13 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Check important sectioned area by using Cross Section Generation of 21 Mil. Mesh : 3.5 sec
Auto Meshing
3-clicks is enough for mesh generation! ▶ Find the best meshing condition automatically
▶ Check thin sectioned area automatically
▶ AnyCasting S/W has Uniform / Variable / Auto Mesh System
14 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Parallel process
Up to 2-times Analysis Speed Improvement ▶ Test PC Performance
- Intel i7-4770 3.4GHz / RAM 16GB
▶ Analysis Type
- Filling & Solidification
(1 CPU) (8 CPU)
15 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Advanced Material Database
User can Make Specific Material Database ▶ Just Input Chemical Composition of Material
▶ Material Database be calculated in a few second and apply to anyPRE
Input Chemical Composition Calculate Thermal Properties
Input Calculated Thermal Properties
16 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Trace of Curved Boundary of Mold Interface
Trace Mold Interface by Sub-divided Mesh (Scheme of Cut-Cell Method)
Boundary Cell for
Trace Interface Surface
Fluid Cell for
Pressure Interpolation
Trace Curved Boundary of Mold Interface
Make Sub-divided Mesh (Meshing Condition Control)
Trace Interface Surface in Boundary Cell using Sub-divided Mesh
17 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Plexiglass-water Model Experiments
Filling Accuracy Comparison with Plexiglass-water Model :
▶ Gravity Casting
Hybrid Scheme (Real Flow)
Experiment General FDM Solver
Fluid Fills Runner Partially (Experiment & Real Flow)
Filling Flow goes Faster along the bottom of Runner (same)
(movie file) (movie file)
18 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Filling Accuracy at Wall of Sand Mold - 1
Filling Accuracy in the Casting of Cat Iron Product
▶ Ductile Cast Iron / Sand Casting
Cavity Riser
Runner
Filter
Runner
Core
Core
Bracket, Weight : 42 Kg
FCD 600, Green Sand / Shell Core
Hybrid Method (Real Flow)
General FDM
Solver
G2 G3
G4
G1
Gate 4, Filling Flow is Weak,
It doesn’t Contribute to
Initial & Whole Filling Process.
G2 G3
G4
G1
Gate 4, Filling Flow is Main Stream,
It Fills near Gate 4 Fast,
Move Forward during Filling Process
19 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Hybrid Scheme (Real Flow)
General FDM
Solver 50% Filled
Temp. Distribution
100% Filled
Temp. Distribution
Gate 4, Filling Flow is Weak,
Gate 4, Temp. is Lower,
Lowest Temp. shows at
Center Area.
Gate 4, Filling Flow is Strong,
Gate 4, Temp. is Higher,
Lowest Temp. shows at
Right Area.
Changes :
Metal Structure,
Sol/ Shrinkage,
Miss-Run,
Sand Drops,
Crack Area, etc.
Filling Accuracy at Wall of Sand Mold - 2
Temperature Distribution during & after Filling
▶ Ductile Cast Iron / Sand Casting
20 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Tracing of Retained Melts - 1
RMM (Retained Melt Modulus) or RMS (Retained Melt Surface)
▶ Tracing of Retained Melts, and Calculate Modulus or Surface Area mainly for Macro Shrinkages
21 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
RMM or RMS
▶ Calculate Volume/Surface and Modulus mainly for Macro Shrinkages
Tracing of Retained Melts’
Volume and Surface
..
....
MR
MRMR
S
VM
RMM :
Retained Melt Modulus
Coupling RMM or RMS with Probabilistic Model
PM :
Probabilistic Model
Shrinkage Size change
Distribution of total Shrinking Volume
Tracing of Retained Melts - 2
22 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Theory & Dev. of Probabilistic Model
Shrinkage Probabilistic Model :
▶ Predict Macro & Micro Shrinkage Size & Range
Shrinkage Probability (Psh)
Cumulated Frequency (ω)
0 1 ω’
β’
0
1
'1
0 dPSh
'
'
''
'
'
''
)1(2sin1
2cos)1(
for
for
PSh
Shrinkage Probability :
Shrinkage Conservation :
β’ : Shrinkage Potential
Calculated Shrinkage
Intensity be Analyzed
by Probabilistic
Distribution
Total Shrinkage Volume
by Alloys & Volume change
by Casting Conditions
Determine Size Range
(Ref. Sung-Bin KIM, etc., Korea Foundry
Society’s Conference, 2001)
23 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Comparison of Coupled Analysis
▶ RMM & G/V with Probabilistic Model
RMM (Retained Melt Modulus) G/V Model, Niyama
Coupled RMM + PM Analysis Coupled G/V(Niyama) + PM Analysis
Tracing of Isolated Retained Melts
Mostly Predict Macro Shrinkages,
Sometimes Micro Shrinkage, as well.
Micro Shrinkages were Calculated
by Insufficient Liquid Feeding into Dendrites,
It Shows Shrinkages of Various Size
at Broad Area of Casting.
Coupling RMM & G/ V with Probabilistic Model
24 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Feature of Sand Casting (Cast Iron / Cast Steel)
Contents
1. Filter
2. Mold Erosion / Sand Drop
3. Core Gas
4. Exothermic Sleeve
5. Exothermic Powder
6. Cast Iron
7. Shrinkage (Critical Solid Fraction)
8. Shrinkage Volume
25 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Accuracy Flow include Filter for Stable Filling
▶ Exact Filter Analysis & Consider all Directions
Sprue
Runner
Filter
No Filter Case Filter Case
4 Direction Flow
under installed
Filter Condition
Filter Case (Pressure) Filter Case (Velocity)
keep
stable
pressure
keep
stable
velocity
26 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ kind of Mold Material & Melt Temperature are very Important
Mold Erosion & Sand Drop Model
velocityImpactV
angleimpactofFunctionf
particlesofionConcentratC
constanttalEnvironmenK
constantMaterialK
smgrateErosionEr
env
mat
)(
)/(
)(fCVKKEr n
envmat
The Relationship between Erosion Rate and Impact Angle The Relationship between Erosion Rate and Velocity
27 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Compare Horizontal Design and Vertical Design
Sand Drop Test by using Cylinder Block
Horizontal
Casting Design
Vertical
Casting Design
28 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Melt Velocity Distribution between Water Jacket and Core : Cylinder Block
Observe Melt Velocity During Filling for Judge Sand Drop
Horizontal
Runner
Design
Vertical
Runner
Design
The rapid velocity of melt can be a cause of sand drop defect
29 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Mathematical Formulation of Core Gas
Core Gas Model
- Movement of Gas in Porous Core : Darcy’s Flow
- Core Gas Pressure : Ideal Gas Raw
- Mass Transport Equation
- Solid Binder Decomposition Rate : Arrhenius Relationship by Pyrolysis Study
- Movement of Gas in Melt : Basset-Boussinesq-Oseen (BBO) equation
Out Gas from Core (g) Gas in Cavity (g/cm3)
Cast Iron
Cold Box Sand Core
Core Print
30 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ kind of Mold Material & Melt Temperature are very Important
Tracking Core Gas during Filling
Horizontal
Runner
Design
Vertical
Runner
Design
Horizontal design has higher possibility of Core Gas defect than Vertical design
31 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Exothermic Sleeve by Numerical Analysis
Exothermic Sleeve Model
- Insulating Sleeve : Sleeve for just adiabatic effect
- Exothermic Sleeve : Automatically generate a heat when contact melt
)()(
)(0
]/[:
)()(
int
3
ionIg
Ignition
b
b
b
Ttf
T
cmscalRateGenerationHeat
tTkTVt
cT
Main Factors for Calculating Exothermic Sleeve
• Sleeve Type
• Burning Time
• Ignition Temperature
• Heat Rate
32 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Simple Model Test : No Sleeve / Sleeve (Low & High Effect)
Exothermic Sleeve Model
- Insulating Sleeve : Sleeve for just adiabatic effect
- Exothermic Sleeve : Automatically generate a heat when contact melt
No Sleeve
22mm
Low Effect Sleeve High Effect Sleeve
42mm
33 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Exothermic Powder by Numerical Analysis
Exothermic Powder Model
- Raise the Feedability of Riser for reduce the shrinkage defect
- Generally, be used Large Ingot & Huge Cast Steel Product
Main Factors for Calculating Exothermic Powder
• Exothermal Area after Filling
• Surface Heat Flux by Time
• Surface Heat Temperature by Time
][:
]/[:
)()(
2
cmdistanceSurfacex
cmscalFluxHeatSurface
tx
TkTVt
cT
s
s
s
s
Spread
Exothermic Powder
Control
Solidification Direction
34 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Exothermic Powder by Numerical Analysis
Exothermic Powder Model
- Raise the Feedability of Riser for reduce the shrinkage defect
- Generally, be used Large Ingot & Huge Cast Steel Product
Shrinkage Defect
Shrinkage Defect
Use Only Exothermic Sleeve Use Exothermic Sleeve & Powder
35 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Predict Phase Distribution & Mechanical Properties
Cast Iron Module
- Consider Effect of Chemical Composition (Si, Mn etc..,)
- Consider Fading Effect of Inoculation
36 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Predict Phase Distribution & Mechanical Properties
Cast Iron Module
- Consider Effect of Chemical Composition (Si, Mn etc..,)
- Consider Fading Effect of Inoculation
Gray Cast Iron : A48
Phase Distribution of Pearlite
Gray Cast Iron : A48
Mechanical Property of T〮S
37 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Selection of CSF (Critical Solidification Fraction)
▶ Selection of CSF at Mushy Zone for Output of Solidification Info.
(Ref. Dongmei Liu, Xinzhong Li, etc.)
(Ref. D.M. Stefanescu, etc. 1985,
Y.X. Li, B.C. Liu, C.R. Loper Jr., 1990)
(Ref. D.M. Stefanescu, L. Dinescu, 1979)
Output of Core Sol. Info. :
- Retained Melt Surface
- Retained Melt Volume
- Temperature Gradient
- Cooling Rate
- Solidification Time
- Local Solidification Time
- Interface Moving Velocity
etc.
Shrinkage Prediction Model
Shrk Size, Position, etc. Change
0.1~0.3
0.5
0.7
CSF :
Critical Solidification Fraction
38 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
Mismatch between Actual Shrinkage & Analysis
▶ Mismatch between Actual Shrinkage and Simulation Prediction
Defect 1
Defect 2
Actual Shrinkages in Factory Simulation Prediction ( RMM + PM )
No Shrinkage Defects
in Simulation
Shrinkages are
Too Close to
Core
No Shrinkages
in Actual Castings
▶ Current Shrinkage Model and CSF in Simulation
1. Material : GCD600 (KS Standards)
2. Shrinkage Model : RMM (Retained Melt Modulus)
3. Total Feeding Ratio =0.7(70%), CSF (Critical Solidification Fraction) =0.5(50%)
39 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
CSF=0.1 CSF=0.2 CSF=0.3 CSF=0.4
Reta
ine
d M
elt M
od
ulu
s
Reta
ine
d M
elt S
urfa
ce
▶ Comparison of RMM & RMS with Variation of CSF
Comparison of Shrinkage Model & CSF - 1
40 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
CSF=0.5 CSF=0.7 CSF=0.9
Comparison of Shrinkage Model & CSF - 2
▶ Comparison of RMM & RMS with Variation of CSF
Reta
ine
d M
elt M
od
ulu
s
Reta
ine
d M
elt S
urfa
ce
41 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Comparison of RMM & RMS (CSF=0.1, Feeding Ratio=0.9)
Section Position for
Shrinkage Defects
Observation
A A’
C C’
D D’
B B’
Actual Shrinkage
Pattern & Positions
Coupled
RMM + PM
Coupled
RMS + PM
Comparison of Shrinkage Model & CSF - 3
42 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
A A’
C C’
D D’
B B’
Section Position for
Shrinkage Defects
Observation
Actual Shrinkage
Pattern & Positions
Coupled
RMM + PM
Coupled
RMS + PM
▶ Comparison of RMM & RMS (CSF=0.1, Feeding Ratio=0.9)
Comparison of Shrinkage Model & CSF - 4
43 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Basic Assumption
Shrinkage Volume Model
- Shrinkage Rate of Liquid Pocket be proportional to it’s volume
- Total Shrinkage Volume is Same as Total Liquid Pocket Volume
1V2V
▶ Basic Equation
- Shrinkage Volume of Isolated Liquid Pocket
s
n
ishr
i fVV
VV
0
shr
s
shr
n VfVV 00
fractionSolidf
ratioShrinkageVolume
pocketiofVolumeShrinkageV
pocketiofVolumeV
VolumeTotalV
s
shr
i
i
:
:
:
:
:0
44 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
▶ Consider History of Solidification & Liquid Pocket Size
Shrinkage Volume Model
▶ Express an Absolute Unit (cc) for Shrinkage Volume
Cast Steel : CG 8M
Solidification Pattern Shrinkage Volume
45 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved
AnyCasting Co., Ltd
AnyCasting Co., Ltd.
www.anycasting.com
Headquarter B-16F Woolim B/D, 583 Yangchun-ro,
Gangeso-gu, Seoul, Korea
TEL 82-2-3665-2493 FAX 82-2-3665-2497
Gimhae Plant 123-18 Gasan-ro, Hallim-myun, Gimhae-si,
Gyeongnam, Korea
TEL 82-55-345-2016 FAX 82-55-345-2017
Thank You !