Casting Simulations - MDXmdx2.plm.automation.siemens.com/sites/default/files... · 2018. 5. 6. ·...
Transcript of Casting Simulations - MDXmdx2.plm.automation.siemens.com/sites/default/files... · 2018. 5. 6. ·...
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Casting Simulations with
STAR-Cast
Julian Gänz, CD-adapco
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Need for Casting Simulation
Processes
Permanent Mold
Tilt –Casting
Low Pressure-Casting
High Pressure Die
Casting
Continuous Casting
...
Lost Mold
Sand Casting
Precision Casting
Centrifugal
Bridgeman
...
From Modern Casting
“2010 world census casting production”
Material Cost/tonne [$] Relative
Carbon Steel 550 1
Cast Iron 830 1,51
Aluminium/alloys 2220 4,0
Titanium /alloys 17 000 30,9
38,16
19,4
9 13,6
Market Overview [Mio tons]
Grey Iron
Ductile Iron
Steel
Non Ferrous alloys
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• Variety of processes and materials
• Sophisticated geometries
• Simulation can help to meet the different and often contradicting demands
– Requirements
• Mold filling with solidification
• Defect Prediction
• Design tool
Need for Casting Simulation
12000 30000
100000 120000 150000
Tool Cost [$]
Fro
m A
ustin G
roup 2
002
Call for advanced
casting processes
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• Best of both worlds
– Provide state of the art of casting simulation solution by combining the
engineering experience of two companies which have a long-standing
track record in providing CAE solutions and casting processes for over
25 years
– Established casting solution STAR-Cast
Strategic Partnership
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• First released in 2009
• Dedicated design and engineering tool for the casting engineer
• Core -Capabilities
• Multiphase
• Resolution of the molten flow and filling front
• Model phase change
• Dedicated material database
• Dedicated User Interface
• STAR-CCM+’s state of the art meshing
STAR - Cast
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• Speaking the language of the casting engineer
• Quickly adaptable to simulation needs
The Process
Geometry
• Any given CAD data
• 3D-CAD Modeller
Mesh
• Fluid /Solid Interfaces
• Appropriate meshing models
Physics
• Adapt to simulation goal
• Expandable
Post processing
• Transient Postprocessing
• Criteria functions, defect analysis
• VOF
• Isothermal- gating design
• Thermal - cooling/ solidification
• Particles/ erosion
Filling
• Progress of Solidification
• Influence on flow
• Misruns and cold shut Solidification
• Piston Motion
• Tilting
• Rotation Motion
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• A dedicated Material Database is available in STAR-Cast, pooling
all relevant material information for the casting engineer
Industrial Challenge - Materials
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• Mushy / Slurry Zone
– Transition from liquid to solid leads to partially solidified areas
– Carman Kozeny approach
• Solid - Flow Stop
– Complete stop of flow in solidified areas
Industrial Challenge - Solidification
Liquid Mushy Solid
fL= 0.0 fL= 0.3 fL= 1.0
vvK
Cv
Kx
p E
i
180f
)f1(),f(K
22
2s
3s
2s
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• Deduct additional information about the solidification process
and the overall quality of the cast
• Gather Temperature gradients, cooling rates and local solidification times
• Compute criteria functions, such as Niyama or G/v criterion
• Estimate porosity characteristics
Industrial Challenge - Defect Prediction
centre line porosity
Ref: Access, STAR-Cast 1.10
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• Phase selective wall porosities for VOF- Phases
– Capture the venting effect of a porous mold, core ( i.e. Sand, Investment
mold)
Industrial Challenge - Porous molds
Porosity to low Calibrated porosity
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• Multi region problem ...
– Complex Geometry
– Fluid Cavity
– Surrounding Air
– Different solids ( mold, cooling
iron ..)
... Meshing requirements:
– Easy surface repair
– Multi region Volume meshing
– Prism layers
– Cell count effective meshing in
thin areas
Industrial Challenge - Complexity
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Investment Casting: Shell generation
• For precision casting
– Dipping a wax model into a ceramic
based slurry
– Ceramic slurry dries and builds the
mold for the casting
– Wax is removed in an autoclave
Automatic shell mold generation
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• Shell mold generator
– Mimics a manufacturing process
– Based on local curvature
Investment Casting: Shell generation
Investment Casting
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• Challenges in Investment Casting
– Thin-walled components with designs at the limit of producibility
– Late design freeze, thus shorter development cycles
– New materials
– New processes
Investment Casting
Courtesy of
Access e.V.
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• Answers Engineers are seeking
– Sensitivity analyses for process parameters, running and gating system
– Geometrical parameter studies
– Enhancement and conservation of raw materials and reduction of overall
manufacturing cost
Investment Casting
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Example of a mould-filling optimization
Initial setup Optimized setup
Sprue cup
Crucible
Courtesy of
Access e.V. &
CD-adapco
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Example of a mold-filling optimization 1
7
Non-optimized Optimized
Simulations show that in a non-optimized distributor the liquid metal
keeps rotating in the distributor for a longer time before entering the
sprue
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• What kind of Defects are of relevance for Investment
Castings:
• Misruns
• Porosity
• Freckles
• Stray grain formation
• Segregation
• Hot tearing
Investment Casting
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Predictions of misruns in a gravity-cast LPT blade 1
9
Shell
Mould
Runner
Blade
Schematic diagram of the process Polyhedral Volume Mesh
Sprue
Inlet
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Comparison of simulation and casting trials
Gravity casting, Access
TechCenter
Value of secondary dendrite arm spacing was obtained from microstructure measurements
Magnitude of velocity Temperature
Courtesy of Access e.V. &
CD-adapco
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DS/DX Castings: Stray Grain Formation
• Stray grains form when
corners of the part solidify and
there is no connection to the
main solidification front.
Marked corner will show a stray grain
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• Enhance accuracy, robustness and ease of use for a wider range
of casting processes
• Include further solidification models
– Ductile Iron, Grey Iron
– Composite castings
• Next STAR-Cast release:
» Fully Based on STAR-CCM+
Looking ahead
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• Latest solver and meshing capabilities
• Modern and easy handling
• All the physics to carry out casting simulations
– Material Database
– Shell mold generator
– Defect prediction
• Add on module to STAR-CCM+
STAR-Cast embedded in STAR-CCM+ : v8.02
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• Dedicated mesher for investment
casting
– Automated Region generation
– Prism Layer + Embedded Thin Mesh
in thin areas
• Streamlined Workflow
• Simple set of input variables
STAR-Cast embedded in STAR-CCM+: 8.04
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• Process driven GUI for casting applications:
– New approach to STAR-CCM+
– GUI adapts to the selected casting process
– “Best Practices” are stored
– High level of automation
– Guide the user through process
STAR-Cast embedded in STAR-CCM+ : Outlook
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• Concept
• Expose only required functionalities
• Use casting terminology
• Shorten the learning curve
• “Conditions”: reusable
• Input is stored in an XML file
STAR-Cast embedded in STAR-CCM+ : Outlook
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Casting Simulations with
STAR-Cast
Julian Gänz, CD-adapco