AnyCasting Software Intro SAND Print

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


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


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

Cast Iron Module

Eject Pin Module

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


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


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


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


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


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

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


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


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)


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


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


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


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)


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


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


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

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


▶ 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

Ignition

b

b

b

Ttf

T

cmscalRateGenerationHeat

tTkTVt

cT

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

cmdistanceSurfacex

cmscalFluxHeatSurface

tx

TkTVt

cT

s

s

s

s

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


▶ 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


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


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%)


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


CSF=0.5 CSF=0.7 CSF=0.9


▶ 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


▶ 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



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)



▶ 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


▶ 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


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 !

AnyCasting Software Intro SAND Print

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