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Precision in Casting Simulation
Above: (Right) The complete die casting process can be visualized with STAR-Cast, including the filling of the pouring chamber, the shot curve, the inflow and solidification of the metal, and the entrapment and extrusion of air. (Left) Die casting machine, image courtesy of Bühler AG.
Above: Coupled mold filling and solidification. Accurate melt flow calculations allow the tracking of oxide inclusions.
CD-adapco is the leading global provider of full-spectrum engineering simulation solutions for fluid flow, heat transfer and stress, including CFD software, CAD-embedded CFD options, CAE consulting services and training.
www.cd-adapco.com
Access e.V. is a successful provider of innovative casting technologies. Activities cover the full range of development tools for dedicated process simulation, material design and construction and operation of pilot plants, including newest equipment for quality control.
www.access-technology.de
ResellersAustraliaCD-adapco [email protected]
Israel ADCOM Consulting Services (Shmulik Keidar Ltd.)[email protected]
New ZealandMatrix Applied Computing [email protected]
RussiaSAROV Engineering [email protected]
South AfricaAerotherm Computational [email protected]
TurkeyA-Ztech [email protected]
Corporate HeadquartersCD-adapco60 Broadhollow RoadMelville, NY 11747USA
+1 631 549 [email protected]
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Asia-Pacifi cBangalore • Beijing • Busan • Chennai • Pune • Seoul • Shanghai • Shin-Osaka • Shin-Yokohama • Singapore
Bringing Simulation Excellence to the Casting IndustrySTAR-Cast is a powerful casting simulation module jointly developed by Access e.V. and CD-adapco. Drawing on CD-adapco’s 35 years of expertise in thermal-fluid simulation and Access’ 29 years of experience in casting and metallurgy, STAR-Cast integrates industry-leading CFD technology with the specific models required by the casting engineer, and brings a new level of precision into casting process simulation for the manufacturing industry.
State-of-the-Art Technology, Unique FeaturesSTAR-Cast utilizes STAR-CCM+® free surface modeling technique combined with the melting and solidification model to study investment, high and low pressure die, centrifugal, tilt die and sand castings. A number of unique features are available to the user of STAR-Cast, including mushy zone & flow stop modeling, as well as criteria functions for defect prediction such as shrinkage, porosity & cooling rates. In addition, the newly added dimensionless Niyama criterion extends the capabilities of the previous version.
STAR-Cast is an entirely new concept in casting simulation that for the first time places industrial strength simulation technology in the hands of foundrymen, casting designers and tool makers. The partnership between CD-adapco and Access has resulted in a formidable tool that will lead to unprecedented levels of innovation and cost reduction in industrial casting.
Steve MacDonald, CD-adapco President
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Predictive Mold Filling AnalysisThe strong emphasis on fluid mechanics enables STAR-Cast to accurately simulate the mold filling process and predict the defects that might result from the flow. The multiphase approach allows the capture of the melt free surface, including surface tension and fragmentation, and provides unrivaled insight into the mold filling. Entrapped air can be tracked throughout the casting system, highlighting insufficient venting of the mold. STAR-Cast extensive motion modeling capabilities allows the effects of any motion applied to the casting system, such as rotation or piston motion, to be directly computed. Finally, since flow patterns and solidification effects are calculated simultaneously, the influence of the mushy zone on the mold filling is immediately visible and phenomena such as misruns or cold shuts can be detected at an early stage of the design cycle.
Accurate Defect Prediction Defect prediction is based on the precise computation of the temperature, pressure, flow velocity, and solidification process. The significance of the technically most relevant criteria functions for microstructure properties, e.g. dendrite arm spacing, micro-porosity, and columnar-equiaxed transition, correlates with precision. The multiphase approach in STAR-Cast enables the tracking of air entrapment and oxide inclusions.
Left: Gravity investment casted Hastelloy X bar. A good agreement was found between the macro-shrinkage prediction using STAR-Cast and the trial casting[1].
Right: Datasets stored in STAR-Cast are easily accessible via the user interface.
Material Data STAR-Cast contains a customizable database with thermophysical and thermomechanical data for the most common alloys and mold materials, including specific and comprehensive documentation. In addition, a database builder allows the user to import, maintain and edit proprietary material data.
References:[1] Adjustment of Numerical Simulation Model to the Investment Casting Process, E. Anglada, A. Meléndez, L. Maestro, I. Dominguez, Proceedings of the 5th Manufacturing Engineering Society International Conference – Zaragoza – June 2013
Above: Comparison of simulation (left) and experimental (right) results. The simultaneous computation of flow and solidification patterns using the enhanced mushy zone model in STAR-Cast allows for an early detection of misruns and cold shuts.
STAR-Cast is the casting add-on embedded in the powerful CAE software STAR-CCM+. It features a dedicated Casting User Interface (CUI) whose menu reflects the thinking and needs of casting engineers and the stages of real casting processes. The interface is an all-in-one tool from CAD to post-processing, including an automatic shell mold generation tool for investment casting.
The process-driven simulation approach allows the user to load configurations and save case studies with little manual interaction, ensuring repeatability. The guided workflow guarantees an efficient simulation setup so that process variations can be quickly evaluated.
STAR-Cast benefits from the state-of-the-art CAD-to-mesh pipeline of STAR-CCM+: import of native CAD or tessellated data and easy-to-modify designs based on simulation results.
STAR-Cast ApplicationsPermanent Mold Casting • High Pressure Die Casting (new) • Low Pressure Die Casting • Gravity Die Casting • Tilt Die Casting
Investment Casting • Gravity Investment Casting • Pressure-assisted Casting • Centrifugal Investment Casting • Bridgman Process
Sand Casting • Gravity Sand Casting • Roll Over Casting • Centrifugal Sand Casting
Auxillary proccesses • Pouring analysis
CADImport
ProcessSetup
Solve EvaluateDesignMaterialsMeshing
Right: Distribution of non-metallic inclusions in a six-strand tundish. The velocity distribution inside the liquid steel is also shown. Image courtesy of Georgsmarienhütte GmbH.
Above: Simulated and experimental results were compared for various crucible tilting curves. The splashing of the melt flow on the crucible was optimized versus the tilting curve and axis of rotation, thus reducing the size of the skull (waist metal). The optimized design is shown on the right.
Right: STAR-Cast now includes a High Pressure Die Casting module, providing a user-friendly, powerful tool to simulate HPDC processes from dosing to defect prediction.
NEW
Key Features A Streamlined Workfl ow Casting Processes
