Sand Casting Processanycastsoftware.com/file/any/Sand/common/AnyCasting...Total Analysis of All Casting System 3-D Mold Filling Porosity, shrinkage/Solidification, Mold 3-D Thermal

1 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

Sand Casting Process

AnyCasting Advanced Casting Simulation Software

Introduction of AnyCasting Functions

TM


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)

Sprue

Drag

Core

Pins

Cavity

TM AnyCasting

Filling Temperature

Core Gas Shrinkage

Predict Several Defects (SAND)


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


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 Eject Pin Module anyPOST Reader

AnyCasting Extensible Module

AnyCasting Standard AnyCasting Performance


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


SW Configuration


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


Solving

- Using Multi Core Process

- Dramatic Decreased Solving Time

SW Configuration



Observation

Fluid - Entrapped Air / Gas - Oxide - Temperature - Velocity - Leakage

Solidification - Final Solidification Area - Micro / Macro Shrinkage

SW Configuration


Filling Sequence Temp. Distribution

Core Gas

Cast Iron Module - Tensile Strength

Melt Velocity

Solidification


Development Roadmap

V2.0

V3.0

V4.0

V5.0

V6.0

V6.1

V6.3

V6.5

- Real Flow - Filter - Auto Report - Calculating Properties - Multi Language - Core Gas

- Jmat-Pro Import - Result Manager - Cross Section Save - Misrun - Fluid Rendering - anyPOST Reader

2005 2010 2013 2015

2008 2012 2014 2017

- Oxide / Inclusion - Shot Sleeve - Vacuum - Advanced Melt Setting - Thermal Stress

- Real Shape - Large Ingot - Centrifugal Casting - Chinese Version

- Multi Core Process - Cast Iron - Eject Pin

- Auto Mesh - Quantitative Analysis - Result Combination - Gas Entrapment - Advanced Cyclic Setting

- Enhanced Particle Tracing - Advanced Channel - Exothermic Sleeve - CPU Core Setting

- Solver Speed Up - Win 10 Support - Channel Import / Export - Shrinkage Volume


Exact View by Dynamic Arbitrary Section

Observe Inside of All Entity Parts ▶ Dynamic Moving Section : X, Y, Z 3 Direction & Free Direction ▶ Detail Observation of STL Geometry in anyPRE & Calculation Result in anyPOST

AnyPRE Process AnyPOST Process

Show Section Only

Rotating (Free Section) Moving


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


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)


Advanced Material Database

General DB User DB Advanced Material (add on function)

User can Select 3 Database System ▶ General DB : anyDBASE has several commercial metal / non-metal database ▶ User DB : User can make database file by using anyDB application ▶ Advanced Material : User can calculate material properties by using thermal property calculator


Advanced Material Database

Import Jmat-Pro Calculation Result File ▶ Enable to Import via File without License ▶ Enable to Input Material Properties that are not in Basic Database


Trace of Curved Boundary of Mold Interface

Using Hybrid Flow – Porous Media Method + Cut Cell Method ▶ Trace of curved boundary of mold interface by sub-divided mesh ▶ Calculate primitive variables at selected grid

Cell Center : uc, vc, wc, Vf, P, T, ρ, Cp, k

Face Center : uj, vj, wj, Aj

Obstacle

Fluid

1. Preliminary Calculation at Staggered Grid

2. Pressure Iteration at Un-staggered Grid → Immersed Cell (Porous Media Scheme)

Embedded Cell Approach When Needed

Scheme of Cut-Cell Method (Sub-Divided Mesh)

Scheme of Porous Media Method

Boundary Cell for Trace Interface Surface


Plexiglass-water Model Experiments

Filling Accuracy Comparison with Plexiglass-water Model : ▶ Gravity Casting

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)

Real Flow Solver (Porous Media + Cut Cell Media)


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


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


Prediction of Macro Shrinkage

PM + RMM (Retained Melt Modulus) or RMS (Retained Melt Surface) ▶ Tracing of Retained Melts, and Calculate Modulus or Surface Area 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 calculation by Distribution of total shrinking volume

RMS : Retained Melt Surface

Shrinkage Strength

PMM Result

Shrinkage Size

PMM + PM Result


PM + Niyama Criterion / Feeding Efficiency ▶ G/V with Probabilistic Model

Prediction of Micro Shrinkage - 1

Niyama 0.1

=

RGCNiyama

0.1

=−

sNiyamaM t

GC

5.0

/

=

VGC EffF

Modified Niyama

Feeding Efficiency

Criterion Developers Year

G Bishop et. Al. 1951

G / V s Davis 1975

1 / V sn Khan 1980

G / R 0.5 Niyama 1982

G /V s Lecomte-Beckers 1988

G 0.33 / V s

1.67 Lee et. al. 1990

G 0.38 / V s

1.62 S.T. Kao et. al. 1994

1 / t sm V s

n F. Chiesa 1998

Coupling G/V Criterion with Probabilistic Model

(Ref. Minami Rin, July 2005)

Shrinkage size calculation by Distribution of total shrinking volume

Shrinkage Strength

Niyama + PM Probabilistic Model

Shrinkage Size



Micro Porosity ▶ Generation Mechanism of Micro Porosity

1. Generation of Nuclei

2. Gas & Solute Accumulate at Liquid / Solid Interface

3. Generation of Nuclei of Gas Bubble & Growth

4. Growth of Bubble Is Stopped by Surrounding Dendrites

5. Bubble Is Isolated & become Micro Porosity after Sol. Finished

Gas (which has been Soluble in Melt) Accumulates at L+S Interface during Solidification. If Partial Pressure of Gas is Increased by Gas Concentration, Gas Bubble is Generated. Size of Bubble depends upon Gas Solubility, this depends upon Temp., P, Composition, etc. Gas Bubble Isolated by Dendrite Network in Mushy Zone in Later Sol. Stage.


Predict Micro Shrinkage Not Relating Retained Melt & G/V


N2 Gas Porosity in Steel Casting Melt Pressure

Gas Partial Pressure Prediction by RMS+PM(Probabilistic Model)

Gas Pressure > Melt Pressure + Insufficient Feeding Micro Porosity Defects


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. Pouring Basin & Stopper

7. Cast Iron

8. Shrinkage (Critical Solid Fraction)

9. Misrun

10. Fluid Rendering

11. Virtual Sensor

12. anyPOST Reader


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


▶ kind of Mold Material & Melt Temperature are very Important

Mold Erosion & Sand Drop Model

velocityImpactVangleimpactofFunctionf

particlesofionConcentratCconstanttalEnvironmenK

constantMaterialKsmgrateErosionEr

env

mat

==

===

=

αα )(

)/(

)(αfCVKKEr nenvmat=

The Relationship between Erosion Rate and Impact Angle The Relationship between Erosion Rate and Velocity


▶ Compare Horizontal Design and Vertical Design

Sand Drop Test by using Cylinder Block

Horizontal Casting Design

Vertical Casting Design


▶ 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


▶ 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


▶ 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


▶ 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

Ignitionb

b

b

TtfT

cmscalRateGenerationHeat

tTkTVtcT

φ

φ

φρρ

Main Factors for Calculating Exothermic Sleeve • Sleeve Type • Burning Time • Ignition Temperature • Heat Rate


▶ 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


▶ 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

cmdistanceSurfacexcmscalFluxHeatSurface

tx

TkTVtcT

s

s

s

s

δφ

δφρρ

⋅

+∇⋅∇=⋅∇+∂

∂

Spread Exothermic Powder

Control Solidification Direction


▶ 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


Pouring Basin & Stopper Model

▶ Basin & Stopper Model be used Special Casting Process

- Feed mode can be selected under variable condition (continuously, once..,) - Additional pressure can be set inside of basin during filling - Stopper condition can be set 2 types (time, volume fraction)

Pouring Basin (Melt Feeding Rate) : melt amount be calculated automatically depend on cavity volume Stopper (Volume Fraction) : stopper opens after filling a particular (ex: pouring basin) entity with a certain amount of melt

Filling 20sec Non Stopper

Pouring Basin

stopper

Filling 20sec Stopper : hold 3sec


Pouring Basin & Stopper Model

▶ Basin & Stopper Model be used Special Casting Process

- Feed mode can be selected under variable condition (continuously, once..,) - Additional pressure can be set inside of basin during filling - Stopper condition can be set 2 types (time, volume fraction)

Pouring Basin (Melt Feeding Rate) : melt amount be calculated automatically depend on cavity volume Stopper (Volume Fraction) : stopper opens after filling a particular (ex: pouring basin) entity with a certain amount of melt

Non Stopper Filling time : 3 sec

Stopper Filling Time : 5 sec


▶ Predict Phase Distribution & Mechanical Properties

Cast Iron Module

- Consider Effect of Chemical Composition (Si, Mn etc..,) - Consider Fading Effect of Inoculation


▶ 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


Prediction of Misrun Defect Area

▶ Predict the Misrun Defects caused by Temperature Drop of Melt ▶ During the Analysis, Melt Filling will be Stopped by the Misrun Algorithm ▶ Show Likely-to-be Misrun Area, Show Precise Result

Misrun OFF Misrun ON

Misrun


Observation of Internal Filling by using Fluid Rendering

▶ Melt Display Translucently ▶ Enable to Observe Internal Changes When Checking Filling ▶ Enable to see Internal Results without Cross Section

Fluid Rendering Mode : Off Fluid Rendering Mode : On


Fluid Rendering with Particle Tracing

▶ Particle Tracing Result + Display Fluid Flow ▶ When Observing, It Shows Fluid Flow as Well ▶ Enable to Clearly Understand the Process of Melt Filling by Checking Combined Result


Virtual Sensor

▶ Needless Re-calculation for Check Non-Sensor Installed Area ▶ Enable to View Time/Temperature Graph of Sensor not-installed Area ▶ Enable to View Each Area’s Time/Temperature Graph by Mouse Click

Use Picking Mode by using Mouse Click


anyPOST Reader

▶ Use anyPOST Function in PPT ▶ Insert Analysis Result File(*.acres file) into PPT and Check ▶ Enable to use Various Functions: Rotation, Zooming etc.

anyPOST Reader File (*.acres)

43 ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 43

Homepage : www.anycastsoft.com Tel : +82-2-3665-2493 Fax : +82-2-3665-2497

Thank you

Documents

Sand Casting Processanycastsoftware.com/file/any/Sand/common/AnyCasting...Total Analysis of All Casting System 3-D Mold Filling Porosity, shrinkage/Solidification, Mold 3-D Thermal