Esi Quick Cast

Getting started with QuikCAST™ (HPDC / Shot)

Engineering Simulation for Industry

2 ESI Group Copyright © ESI Group, 2008. All rights reserved.

Getting Started with QuikCAST™ List of CAD Files

casting.stl


Getting started with QuikCAST™ Import CAD Files

1 Select New option from the File Menu


Getting started with QuikCAST™ Import CAD Files (Core)

Browse to define the Study Location

2 Input Study Name

3

4 Click OK


Getting started with QuikCAST™ Import CAD Files (Core)

5 Browse and select the casting_HPDC.STL file

6 Click Open to load the CAD file in the model Window


Getting started with QuikCAST™ Import CAD Files (Casting)

7

Activate Welding Point Operation

Define CAD File Unit System ( casting_HPDC.STL units is MM)

8

9

10

Input Tolerance value (mm)

Activate Automatic Fixing 11 Click OK


Getting started with QuikCAST™ Import CAD Files (Casting)

12 Click YES to continue

QuikCAST gives a description of the encountered problem when analysing the CAD files


Getting started with QuikCAST™ Import the CAD (Core)

HPDC Al geometry has been successfully imported


Getting started with QuikCAST™ Automatic CAD Inlet Creation

Select Mesh Basic Shapes Option from the Model Menu



Select By extrusion option 1

2 Input Extrusion Distance (Piston Chamber lenght)



3 Switch to Wire&Shaded display mode to display the facets

4

Entity selection must be set to Facet

5

Select Facets located on the top of the tube

( SHIFT + left button)

Extruded geometry is automaticallydisplayed for

each new selected facet



Click Close The inlet volume has

been succefully created

7


Getting started with QuikCAST™ Automatic Volume detection/Material Assignment

In order to detect/assign volume materials select Domain Manager Option from the Model Menu


Activate the Create Contact surface option Click Start to Start the Automatic

Volume detection 2

1


4 Volume domains have been detected that need to be renamed and assigned with material properties.

New Surface Domains have been automatically created because the Create Contact surface option has been activated


Select Volume_001 (left click)

1

2

Click View Volume to display the Volume_001


Click Rename

3

Input Volume Domain Name

4


Click Material

5

6 Select Alloy Volume type

7

8

Activate Standard DB

Select AlSi9Cu3 Material from the material list


Repeat the steps to assign names and materials to the other volumes

5 6 7 8 4


Click P to Activate Priority order

9

Change Volume Priority order with the arrows ( Priority order should be defined according to the Filling order)

10


Click Remove to delete the surface domains created during the import and during the automatic fixing sequence

11 Switch to Surface Domain panel

12


Getting started with QuikCAST™ 3D Grid/FD Mesh Generation

Select 3D Grid/Mesh Generation option from the Model menu to generate the Grid


Getting started with QuikCAST™ 3D Grid/FD Mesh Generation

Activate Simplify Method 1

Select all the volumes 2

Input Mininum Size to fix global grid cell size (unit is meter)

3

Click Apply to generate the Grid

4

Click Run to generate the 3D Mesh 5


Getting started with QuikCAST™ Define Gravity Direction

Select Gravity Option from the Process Menu


Getting started with QuikCAST™ Define Gravity Direction

Select PositiveZ direction and check Gravity Direction ( displayed in green) in the model window

1

2

Click OK


Getting started with QuikCAST™ Start the Model Set-up

Select Input Data Check from the Process Menu and a window with all available boundary conditions will appear on the left This window is used to manage all Boundary Conditions (BC) that will be applied to the model


Getting started with QuikCAST™ Set-up the Metal Flow

1 Select Initial Fluid BC (left click) to set up the initial fluid rate for the filling

2 Click on Add... (right click) to open the panel definition


Getting started with QuikCAST™ Set-up the Sand Flow

3

Input 40% and select Initial

4

5 Click OK

Select « Piston» and « Chamber » Volumes in the Volume list (left click)



1 Select Piston BC (left click) to set up the Sand Core Blowing pressure




3 Select Mold Material for the piston Material

4

7 Click OK

Select Velocity Calculator Option to automatically calculate the transition from phase 1 to phase 2.i

6 Select « Inlet/Pressure1 » surface domain

5 Input Direction, Max Displacement and Velocity for phase 1 and 2


Getting started with QuikCAST™ Set-up the Wall Flow laws

1 Select Temperature BC ( left click) to set up the metal injection temperature




3 Select Initial Option

4

7 Click OK

Input Alloy Material Temperature

6 Select « Chamber » and « piston » volume domains

5 Select Filling Option


Getting started with QuikCAST™ Set-up the Virtual Mold

1 Select Implicit Mold BC ( left click) to set up the Virtual Mold Material




3 Input Average Mold Thickness

4

6 Click OK

Select Die Material from the Standard DB list

5 Select the Surface domains having an interface with the die


Getting started with QuikCAST™ Set-up the Wall Heat Transfert

1 Select Die Coating BC ( left click) to set up the Virtual Mold Material




3 Input Average Coating Thickness

4

6 Click OK

Select Coating Material from the Standard DB list

5 Select the Surface domains where the coating is applied


Getting started with QuikCAST™ Set-up the Output Solver Parameters

Select Output Parameter Option from the Calculation Menu


Getting started with QuikCAST™ Set-Up the Output Solver Parameters

3 Activate the Filling Panel

4

6 Click Close

Select by Percent (%) and input a value in the Graphics field. ( This will determine the number of states generated during the calculation

5 Select the Variable Contours needed for post-processing


Getting started with QuikCAST™ Run the Calculation

Select Calculation Start Option from the Calculation Menu



2

1 Activate Standard Calculation Option from the Filling/Solidification Panel

Enter Filling and Solidification Stop Criterias ( Time and/or Percentage of Filling/Solidification)

Click RUN to start the calculation This will open automatically the Monitor Calculation Window

4

3 Activate High Pressure option



> Calculation is running now


Getting started with QuikCAST™ Post-Processing (Visual-CAST)

Select Open option from the File Menu


Getting started with QuikCAST™ Post-Processing (Visual-CAST)

Select *.MCO file in the study directory 1

2

Click Open


Getting started with QuikCAST™ Post-Processing Metal Flow (Visual-CAST)

Select Volumes to load

1

Click OK 2



Select Snapshot Option from the Results menu

3



Select THERMAL in Categories and Temperature in Results to display the temperature results during filling

4

5 If your calculation is still running, click Update to update the last calculated results

6 Select Arrows to display the differents states


Getting started with QuikCAST™ Post-Processing Sand Flow Particules (Visual-CAST)


Getting started with QuikCAST™ Post-Processing Examples (Visual-CAST)

Getting started with QuikCAST™

(HPDC Shot)

Engineering Simulation for Industry Engineering Simulation for Industry

Esi Quick Cast

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