Cast-Designer... Using HDI for riser design 20 Read in the part geometry in 3D CAD data or STL data....

Cast-Designer

-- Full Engineering Solution for Casting Industrials

www.auto-design-online.com

C3P Software: Digital Manufacturing Solution Provider

2

• Focus on virtual manufacture process to help industry to catch up ‘Time to Market’ and ‘Quality to Market’

– Full solution for metal casting and assembly

– Sheet metal forming design and simulation

– Integrate expert system and CAE technology

– Very close research relationshipwith top level research institute and universities.

– Innovation technology compared with tradition design and CAE method, build in upfront analysis.


Cast-Designer International Network

3

C3P Software offices Value add international resellers

• Formally US base company, very care of the development of new business region

– Shift software R&D to Asian step by step since year 2006

– More than 50 industrial projects each year

– Strong support and distributor channel

– Faster development, one major release each year.

Asia Pacific: Australia, China, India, Japan,

Korea, Malaysia, Singapore,Taiwan, Thailand, Vietnam

Europe: Italy, Germany, Hungary, Poland,

Spain, Turkey, Russian

North America: USA, Canada, Mexico

Latin America: Brazil Africa: South Africa, Egypt Over 70 dedicated team members in

the world supporting our products


Product, Partnership, Customer

4

Cast-Designer

Form-Advisor

Geo-Designer

www.core-capital.com

www.ascentvp.com

www.rockfordcapital.com

Our products Solid financial status Partnership and selected customers

The sole solution provider for casting business from part to production.

http://www.core-capital.com/

http://www.ascentvp.com/

http://www.rockfordcapital.com/

http://www.opencascade.org/

http://www.isuzu.co.jp/index.html

http://www.renault.com/renault_com/fr/main/index.aspx


Product, Partnership, Customer

5

Cast-Designer

Form-Advisor

Geo-Designer

www.core-capital.com

www.ascentvp.com

www.rockfordcapital.com

Our products Solid financial status C3P University

The sole solution provider for casting business from part to production.

To help young people familiar new technology and casting business.

http://www.core-capital.com/

http://www.ascentvp.com/

http://www.rockfordcapital.com/


Cast-Designer Solution

6

3D PartDFM Check

QuotationPrepare

GatingSystem

ManufactureProduction

CAE Analysis（FEM + CFD7.2）

AutomaticOptimization

Cast-Designer

SavingCAST(Material)


Casting Process and C3P Software Solution

Example in sand casting


Casting Process and C3P Software Solution

SavingCASTC3P Software

Example in sand casting

Cast-DesignerC3P Software

Cast-DesignerC3P Software


What is SavingCAST?

SavingCAST is a software specially developed for foundries, designed for optimal selection of loads for any type of league. Automatic calculation of casting with cost optimization using the relevant information of the raw material in stock, always within the constraints imposed by the user.

In today’s business environment, the spread sheets are no longer enough. With SavingCAST, it is possible to make your castings at the lowest cost and manage all the production system together.

SavingCAST can save time and money to be competitive in the new global market.

SavingCAST will let you prepare your charges at the lowest cost, saving time, avoiding human error, managing the stock and keeping track of your operations.

SavingCAST also suitable for all casting process.

Reducing costs.

Improving quality.

Optimizing resources.

Contributing to sustainable development.

Achieving operational excellence.


Amount %

1 Iron (Raw) 1,099,971.6 47.58%

2 Scrap Steel 8,955.0 0.39%

3 Salary 562,037.0 24.31%

4 Electric power 64,560.0 2.79%

5 Smoke power 27,444.0 1.19%

6 Bontonite 35,588.0 1.54%

7 steel ball 20,480.0 0.89%

8 mold sand 6,730.0 0.29%

9 Coke 147,963.0 6.40%

11 Silicon sand 2,752.0 0.12%

12 Hardware materials 110,547.0 4.78%

13 Welfare fee 622.0 0.03%

14 repair costs 978.0 0.04%

15 Food expensens 31,330.0 1.36%

16 Rent cost 9,200.0 0.40%

17 transport fee 11,405.0 0.49%

20 Medical insurance 357.0 0.02%

21 others 3,475.0 0.15%

subtotal of production 2,144,394.6 92.75%

23 Sell -Transport fee 49,024.0 2.12%

24 Mgr - Travel costs 25,665.0 1.11%

25 MGr - Office expenses 777.0 0.03%

26 MGr- Insurance 120.0 0.01%

27 MGr - Drink water 1,745.0 0.08%

28 MGr- Hospitality fee 4,907.0 0.21%

29 MGR - Consultation fee 3,600.0 0.16%

30 FA- Interest expense 76,200.0 3.30%

32 FA- Discount fee 5,545.0 0.24%

Subtotal expenses 167,583.0 7.25%

Total costs 2,311,977.6 100.00%

April (in RMB)

DescriptionS/NCost Structure Example

47.97%

9.48%3.62%

24.31%

14.62%

0.00%

10.00%

20.00%

30.00%

40.00%

50.00%

60.00%

Rawmaterial

Poweretc.

Suppliermaterial

Salary Otheroperation

Cost structure

Cost structure example of a sand casting company, the raw material is the main cost and achieve around half of the total cost.


Charging Example – Steel: Result Comparison

Plan1: Experience charging

Result: 17.44 CNY/Kg

NG NG NG

NG



Plan2: Other System




Plan3: SavingCAST




17.44

15.9

13.39

5

7

9

11

13

15

17

19

Experiencemethod

Other system SavingCAST

Cost per Kg

Cost per Kg

Total cost: 348,800

Total cost: 318,000

Total cost: 267,800

Save30,8008.8%

Save81,00023.2%

Reference

For a furnace in 20ton to calculate the total cost


SavingCAST: Advantages of the Program

Very easy to use. One hour training course only!

Efficiency and speed of calculation within the process of production and under constantly changing assortment of charge materials and alloying additives;

Getting the set chemical composition at minimum cost of charge materials;

Sending the received results to the calculation database for their further printing (transfer, processing, etc.);

Multi-language interface of the software;

Flexible business plan for the software license;

The pay back period for SavingCAST has never exceeded one month.


Full Chain of Casting Industrials

16

3D Part

DFM Check

Quotation

Prepare

Gating

System CAE Analysis

Manufacture

Production

1 2 3 4 5

3D Product

Gating System Design

Process Analysis


What is Geo-Designer? (I)

17

• Geo-Designer is a powerful upfront Design for Manufacturing (DFM) tools for designers and manufacturing engineers with innovative technology.

• It accelerates the design process for functions, manufacturability, enabling designs to move to production better and faster.

• Geo-Designer is powerful, flexible, fast and easy to use and provides savings in downstream costs by quality improvement at the design stage.

• Geo-Designer offer a new method to study the part geometry in 3D Iso-surface with flexible transparently, it is similar the x-ray and CT method in industrial.

• Geo-Designer can analysis the product thickness, draft angle or undercut and fillet radius. Ray method and the Mass Distribution Index (MDI) are supported for geometry analysis.


What is Geo-Designer? (II)

18

• Geo-Designer can analysis the heat transfer and distribution for the casting process. The Heat Distribution Index (HDI) analysis is much faster and simple than any numerical simulation method.

• Geo-Designer can make slider analysis to support mould design.

• Geo-Designer can make ejection force analysis for both value and distribution to support ejection pin design.

• Geo-Designer can make core checking and design for gravity casting part.


Geo-Designer Could Be Used for …

19

Mass distribution

Wall thickness

Draft Checking

Fillet Radius

Core checking

Cooling rate

Riser & Gate

Heat distribution

Slider Checking Ejection Force

Chill Design


Using HDI for riser design

20

Read in the part geometry in 3D CAD data or STL data.

Read in the riser, chill and gating system one by one.

Assign different material properties to riser, gating, chill and insulator.

Generate the Geo-Designer model and make HDI analysis.

The last picture show the result of HDI =15. the affection of the chill to heat distribution is clear (the red arrow).

1 Min.

• Design the location of riser

• Check the size of riser


Using HDI for riser design

21

We continue check the HDI in higher value, such as 20, 25, 30 and 35.

The region with arrow is high risk for shrinkage porosity after the casting process. So the user can adjust the size and locations of the risers to achieve a better result.


Application: Geo-Designer for Engine Block

22

Geo-Designer could be used to check the basic information of the part, to guide the product design and provide more detail information for manufacturing process design. The information includes,General thickness of the partSection thickness of the partPart information such as volume, mass, surface area, geometry modules, projection area in X/Y/Z direction

Part Checking:


Geo-Designer for Engine Block: casting checking

23

Geo-Designer provides function for slider checking. The red color region must use slider to help eject the part after casting. This information is very useful for die designer.

Slide checking: Core checking:

Sand core checking is very important for the complex part, such as engine block. It should be useful to check the weak sections of the core at product design stage.


Geo-Designer for Engine Block: Riser design

24

Geo-Designer provides a quick analysis of the thicker wall zone and such information could be used for riser & feeder design.

Region volume and mass in higher HDI could be used for riser size design after consider the riser effectively.



25

Build in riser design functions to provide online riser design capability and check it immediately.

Support box, cylinder, cone and ball design. Support STL import for addition fuse and substrate for more complex geometry.



26

Take the online design object as CAD import and make some fine turning.

Final design after consider the real geometry of engine and casting process.

MDI check

Location?

and

Size?


Ejection force calculation, slider analysis

27

Applicants

Part base analysis in

an express way

3 to 5 min to get the

first result.Slider zone checking to help

mould design

• Ejection force

analysis, locking

force analysis

• Setup the mold

side, and distribute

the ejection pin


Geo-Designer for Part Optimization

28

Example part: Load to Geo-Designer. MDI analysis.

Add control points to move the critical region.

More points could be added in one model.

Part optimization: material be removed.


Geo-Designer for Part Optimization

29

Part optimization: material be removed.



30

3D Part

DFM Check

Quotation

Prepare

Gating

System CAE Analysis

Manufacture

Production

1 2 3 4 5

3D Product


Process Analysis


Casting Costs & Quotation

31

Yearly volumeBatch volumeLead timeYield ratio

Production rateAlloy / MaterialMachine & equip.ManpowerSub-contractother costs

Mould costWorkshop TransportStorageFinancial costManagement costSelling cost

Total costSelling price

ProfitsRevenue

Manufacturing costs

Operation costs

Customer order

Quotation


Casting Costs & Quotation

32

A quotation tools in Cast-Designer for cost calculation. It could be used for cost evaluation after the DFM analysis for all casting process.

This quotation calculator was evaluated by many customers in different casting field.

The user can customize the currency, alloy, machine and manpower cost, then calculate the casting cost based on the production rate, volume, manufacture cost, and other cost.

Finally a multi-language quotation sheet could be generated in Excel file format.

Project Information

Product: Part Name:

Part Number: Enquiry No:

Customer: PO No:

Prepared By: Date:

Comments:

Mass of casting: 3 Kg Casting machine:

Mass of gating system: 1.5 Kg cost per hour: 9.8 /hr

Cycle time: 65 Sec Cost of operator: 12 /hr

Number of Cavities: 1 Casting Alloy:

Production rate: 55.4 pcs/hr

Annual quality of part 400,000 pcs Currency Used:

Production batch size 40,000 pcs

Machine cost 0.187 /pcs Good movement cost 0.007 /pcs

Labour cost 0.206 /pcs Good despatch cost 0.004 /pcs

Material cost 4.05 /pcs Storage cost 0.003 /pcs

Scrap cost: 0.04 /pcs Freight cost 0.57 /pcs

others 0.083 F&A cost 0.1 /pcs

subtotal 4.566 Subtotal 0.684 /pcs

Selling cost 0.184 /pcs Annual sales value

Selling price 6 /pcs Annual total costs:

Profit margin 9.43% /pcs Annual profit:

machine cost 0.187

Labour cost 0.206

Material cost 4.05

Scrap cost 0.04

other cost 0.951

profit 0.566

Demo

C3P Engieering Software Cost sheet

cover

1234-12C1

ABCD

Ben

cover-1

4567

567

2014/8/18

Casting data and production rate

ADC12

Ton350

Machine and casting alloy:

USD

2,173,600.00

226,400.00

Cost structure overview

Cost of manufacturing process Cost of movement and storage

Selling cost and sales price Revenue and profit

2,400,000.00

machine cost

Labour cost

Material cost

Scrap cost

other cost

profit



33

3D Part

DFM Check

Quotation

Prepare

Gating

System CAE Analysis

Manufacture

Production

1 2 3 4 5

3D Product


Process Analysis


Gating System Design Interface

34

Casting system design

Now, all the casting system design functions

have been summarized to one unique window

interface. The unique interface services to all

casting process like HPDC, LPDC, gravity

and investment casting process, also all

casting components like the gating system,

overflow system, cooling and venting system.

More ever, the shot sleeve design is also

redesigned and included in the gating system

design wizard, the vacuum valve setting also

could be analyzed during the shot sleeve

design.


Turn your design concept to 3D data in a quick way

35

1

2

It is really hard for me to make a clear decision before I have a detail 3D casting system…

No problem! Cast-Designer can do that in a few minutes …


Cast-Designer for Casting System Design

36

Cast-Designer BASIC is an efficient 3D CAD tools with expert system special for HPDC

Expert

Power

Platform

An Expert System for Gravity Casting System design to help designer and engineer make a reasonable casting system in a quick way

Designer application Includes riser, feeder, gating system , chill, well and cooling system

Standard alone software based on last Open CASCADE technology or fully integrated to common MCAD system, such as Pro-E, UG NX, SolidWorks etc

Usage

Data

Learning

The design approach is much faster and simple compared with tradition CAD system and fully parametric

Standard and special data exchanger for 3D CAD system and CAE system

Short learning curve and enhance company design ability shortly

Cast-Designer BASIC is an efficient 3D CAD tools with expert system for Gravity Casting


Cast-Designer: Riser & Feeder design

37

Riser & Feeder Design

Build in wizards or calculators to guide the user swiftly towards the optimized design of a feeding and gating system

Riser Design Rule:

• Time condition: Solidification

• Volume condition: predict the delivered volume of open or blind riser or isothermal sleeve

• Distance condition: feeding


Casting Design Advisor

38

Gating System Design Advisor

metal, mass, quality requirement

Casting Volume

Riser & Feeder

Filling Time

Inner Gate

Help solve the solidification problems

Casting alloy, Casting part geometry

Nbs, section area

(Design finished)

Fine turning

Sprue runner

Runner

Speed Up Ratio

Nbs & section area, shape parameters

Design runner, Nbs & section area

Increase ratio of pouring system/Spure: Runner :

inner gate


Template design for Gravity

39

Re-write the one button design engine with new template format.Re-organize the template.

New interface for parameters editing.Much better CAD quality than before, support fillet radius between segments.Support runner in arc curve.


‘Template design’ for Gravity casting

40


Template design for gravity casting gating system

41

Template gating system design procedure Full parametric design, very easy to adjust the shape and dimension.

• Main parameters to control the major dimension and shape minor parameter to control the details.


Cast-Designer: Runner design

42

Gate & Runner Design

Build in wizards or online help to guide the user swiftly towards the optimized design

• Full casting system design (inner gate, runner, Sprue runner, chill, well, cooling system …)

• Very similar interface for all design components

• Multi-objects support, Multi-plan support

• Full 3D model, support draft design concept

• What You See, What You Get work style (WYSWYG)

• Flexible coordinate adjustment, flexible objects operation

• Data template concept, import and export data template.


Cast-Designer: Sprue Runner design

43


Enhance Free Design Functions

44

Enhance free design functions to control the section of runner.

Redesign the toolbar and function buttons.

Control everything in the mouse operation.

Much powerful in 3D runner design.


Free Design Functions

45

• More flexible to control section dimension and

details in mouse and immediately panel.

• Section angle free adjustment (New)

• Smooth curve for connection.


Section Control & 3D Gate Generation

46

More friendly interface for section control and adjustment.

Mouse control the ‘Z’ coordinator for 3D gating system, very simple and easy to use. Now everybody can generate 3D runners.

More parameters in sections for special gating system.


Gating Revise in Free Design

47

1 2 3

3

44

• Reverse Engineering for existed gating system from

ANY CAD system (CAD, STL, mesh etc.)

• Convert to full parametric gating in a few minutes

1. Original gating CAD

2. Fast meshing to split to different

runners

3. Draft runner on existed CAD surface

4. Revise to Cast-Designer digit runner

in fully parametric.


Gating Projection in Free Design

48

1

2

34

Design the gating system in a plane and control the section area /dimension. Also display the core/slider in the main view.

Adjust the section numbers in the projection region. Adjust the section angle (if any)

Project the runner to the slider/core/3D surface.

Obtain the 3D runner with accurate dimension.

• Final result of

gating projection


‘Free Design’ & Complex Gating System

49

3D feature line

3D gating system

In Cast-Designer, the start point has beenshifted to casting part stage sine the systemgenerate gating system directly.

Gating system and simulation of automatic part

Gating system of engine block Gating system of permanent mould gravity casting


Cooling system design

50

New interface for cooling system design.

Support cooling group, channel and segments.

Online wizard for all cooling channel length

Powerful online analysis (unique)

Cooling channel

Heat balance guide

Fast cooling model

Cooling affection analysis


Cooling Channel Analyze: Cooling Affection

51

Combine both the EMDI and fast cooling result together to cooling affection result. The negative value region should take care of.


Win business on the start point

52

Design

Time from ‘Design’

Quality from ‘Design’



53

3D Part

DFM Check

Quotation

Prepare

Gating

System CAE Analysis

Manufacture

Production

1 2 3 4 5

3D Product


Process Analysis


Powerful 3D Mesh Generation

54

CAD

MESH

CAD

MESH

CAD

MESH


Cast-Designer Dual Solver

55

FEM CFD

PK?

Dual Solver Technology

Cast-Designer v7


Design 2

Cast-Designer CPI to check the flow result

56

Design 1

Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.

• The Flow results includes the temperature, flow pattern, velocity, fluid factor, gas entrapment etc.


Design 2

Cast-Designer CPI to check the solidification result

57

Design 1


• The solidification result includes the solid factor, temperature, hot spots, shrinkage porosity etc.


Shrinkage porosity and micro-porosity

58

Cast-Designer CPIResult shows the Shrinkage porosity the yellow one, it was due to the last solidification. And the micro-

porosity, it due to the cooling rate of the solidification process, the red one.

Design 2Design 1


Design 2

Design 1

Mechanical stress and deformation

59

Average Normal Stress

Average Normal Stress

Effective Stress

Effective Stress

Part deformation after casting

Part deformation after casting


• The basic result of stress includes the stress & strain, part deformation, hot cracking and life time.


Design 2

Design 1

Micro-structure analysis the solidification & cooling

60


• The micro-structure results includes the temperature, phase transfer, mechanical properties etc.

SDAS % of Pearlite

SDAS % of Pearlite


Design 2

Design 1

Mechanical properties of the casting part

61



Tensile stress Yield stress

Tensile stress Yield stress


Design 2

Design 1

Mechanical properties (hardness)

62



Hardness (HRB)

Hardness (HRB) Hardness (HRB)

Actual test HRB217.04

226.8


Cast-Designer CPI Flow Chart

63

CAD DataGate System

CPI Meshing

CPI Setup

Cast-Designer CPI

Post Result


Machining Part: defects analysis (Shrinkage porosity)

64


Complex gating system for gravity Casting

65

Casting system design35 min

Meshing with all components and CPI setup 20 min

Mixed meshing for casting part and cores, 323,100 elements for casting

Metal flow was not balance for the three parts Temperature drop too much (right)


Meshing technology in Cast-Designer CPI

66

• Innovation technology for meshing generation

• Very simple for operation

• With coarse mesh, mesh layer and advance geometry mapping (mesh smoothing) technology

• Extremely better for accurate in filling pattern and pouring time

CAD model

Mesh model Enlarge the CAD & Mesh

This model includes 118,544 elements, and take 2 minutes for mesh generation.


Examples of Cast-Designer CPI

67

Cast-Designer BASIC is an efficient 3D CAD tools with expert system special for HPDC

Sand Casting

permanent gravity casting

DISA

Tilt Casting LPDC


Mould assembly for permanent gravity casting

68

CAD Model

Powerful mould assembly function in Cast-Designer

The Cast-Designer technology can not only provide a quick meshing and mesh

assembly, but using the mixed meshing technology to reduce the model size

to minimum. For example, for the above model, the meshing time was only

28 min and full automatic. The affection ratio of the node of casting can

achieve to 47.8%, it is really very high for this kind of applicant.Mesh model

Top Die

Bottom Die

Sand Core

Casting Part

721,320 elements

195,099 nodes

Tetrahedron

436,679 elements

604.052 nodes

Hexahedron

776,328 elements

203,632 nodes

Tetrahedron

976,940 elements

259,331nodes

Tetrahedron

Advance

module


Mould assembly for permanent gravity casting

69

Advance

module

Mixed elements for casting & mould

Powerful mould assembly function in Cast-DesignerThe powerful mesh assembly function of Cast-Designer can reduce the meshing time to 10 to 30 min for any complex model, it is full automatic.

Complex mould with more than 15 components

25 min for mould assembly & meshing


Advance CFD flow solver and applications

70

Advance

module

Simulation result of Cast-Designer CFD Solver vs experiment.The experiment was performed by Dr. Markus Schmid at ARGE Metallguss in Aalen, Germany

(a) X-Ray photo of the actual part

(b) Gas entrapment of simulation result

(c) Flow pattern shows gas entrapment


Mechanical stress and deformation analysis

71

0.6mm outside

2) The dimension of the heat sink was changed after the casting process.

1) The side wall with 0.6mm deformation, match the actual part.

Advance

module


Stress and deformation analysis

72

Mechanical Stress Module:

Cast-Designer with mechanical stress and deformation simulation capability. Thanks the FEM base technology, no addition mesh and couple calculation in Cast-Designer, one mesh for everything.

Simulation result Actual measurement results

Advance

module


Deformation and compensation

73

The deformation simulation can provide accurate result of the part deformation after casting.

The deformation compensation function provides a simple way to correct the part geometry to have an accurate casting result.

Advance

module


Distortion Compensation Solver

74

Advance

module

The deformation simulation can provide accurate

result of the part deformation after casting.

The deformation compensation function provides a

simple way to correct the part geometry to have an

accurate casting result.

(a) Full mould

(b) Hot tearing inducator

(c) Average normal stress

(d) Actual part with crack (after testing)


Microstructure analysis result

75

Advance

module


Distortion Compensation Solver

76

Advance

moduleDesigned casting Shape after casting

Original casting shape

After partcompensation

Casting compensation is a common and useful method to correct the casting distortion after casting, but ask rich experience, and very difficult for complex geometry.

A new Distortion Compensation Solver (DCS) was developed in Cast-Designer. With DCS, the user can simulate the part distortion and make geometry compensation automatically.

It is an iteration method to find the best geometry shape. Finally the adjustment distance of feature points could be reported and use back to CAD system.

This feature is unique in the market.


Distortion Compensation Solver: Example

77

Advance

module


Distortion Compensation Solver: Example

78

Advance

module


Material Encryption

79

Support material encryption by user for the important material data The user can protect their material without addition license The others can use the material but could not read or edit the material

Encrypted material data


Material Database

80

• More industrial level exothermic sleeve had been added to database

• Foseco

• Joymark

• Exochem

• ASK

• AMCOR

• Jodovit

• All above data are validated by simulation and experiment testing

• The data is encrypted.


CFD Solver Parallel Performance (100K elements)

81

mesh size 100K 100K 100K 100K 100K

1Core 2Core 4Core 8Core 16Core

10% 325 270 215 202 212

20% 1613 1400 810 690 669

30% 3528 2993 1612 1277 1224

40% 6419 4983 2675 2048 1905

50% 9730 6986 3718 2748 2524

60% 13484 8984 4711 3498 3281

70% 17411 10757 5775 4361 4072

80% 20335 12406 6919 5299 4786

90% 22956 14348 8196 6420 5554

95% 24657 15422 9112 7235 6072

98% 26819 16762 10462 8058 6471

End

Hours 7.45 4.66 2.91 2.24 1.80

Original model V7.0

0

3600

7200

10800

14400

18000

21600

25200

28800

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

1Core

2Core

4Core

8Core

16Core

0.00

0.50

1.00

1.50

2.00

2.50

3.00

3.50

4.00

4.50

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

1Core

2Core

4Core

8Core

16Core

mesh size 100K 100K 100K 100K 100K

1Core 2Core 4Core 8Core 16Core

10% 1.00 1.20 1.51 1.61 1.53

20% 1.00 1.15 1.99 2.34 2.41

30% 1.00 1.18 2.19 2.76 2.88

40% 1.00 1.29 2.40 3.13 3.37

50% 1.00 1.39 2.62 3.54 3.85

60% 1.00 1.50 2.86 3.85 4.11

70% 1.00 1.62 3.01 3.99 4.28

80% 1.00 1.64 2.94 3.84 4.25

90% 1.00 1.60 2.80 3.58 4.13

95% 1.00 1.60 2.71 3.41 4.06

98% 1.00 1.60 2.56 3.33 4.14

End

Original model V7.0


CFD Solver Parallel Performance (200K elements)

82

1 core 2 core 3 core 4 core I7_6700 8core 10core 16core 20core 32core 40core

12% 1210 925 532 252 113 83 70 92 52 61 73

15% 4812 2704 1840 1154 422 404 246 344 189 216 250

20% 9599 5297 3677 2593 857 1035 515 728 393 453 512

25% 15008 8522 5914 4269 1379 1792 859 1156 645 734 812

30% 21363 11808 8969 6307 2093 2671 1218 1618 927 1063 1192

35% 16408 12354 11601 3603 4239 1978 2744 1591 1604 1969

40% 14792 12726 4312 5307 2521 3264 1948 1932 2299

45% 17303 14752 5160 6527 2945 3899 2476 2298 2760

50% 17057 6331 7760 3435 4593 2934 2689 3228

55% 7637 9095 3969 5454 3427 3154 3767

60% 9354 10515 4584 6341 3942 3687 4284

65% 10940 11857 5292 7292 4423 4224 4772

70% 12674 13268 6042 8313 4907 4828 5509

75% 14411 14860 6802 9367 5424 5414 6097

80% 16125 16413 7624 10296 5977 5950 6652

85% 17963 17390 8466 11178 6445 6448 7249

90% 20076 18444 9445 12305 7095 7132 8013

95% 22197 21720 10860 13572 7929 8061 8915

98% 26839 25530 12665 15910 9226 9539 10718

0

3600

7200

10800

14400

18000

21600

25200

28800

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

1 core

2 core

3 core

4 core

I7_6700

8core

10core

16core

20core

32core

40core

0.00

0.50

1.00

1.50

2.00

2.50

3.00

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Orginal

8core

10core

16core

20core

32core

40core

The test machine was:

Intel Xeon CPU E5-2680

CPU in 2.8GHZ

2 Processors

20 physical core

40 logical core

64GB RAM

Windows 10 64 bits



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3D Part

DFM Check

Quotation

Prepare

Gating

System CAE Analysis

Manufacture

Production

1 2 3 4 5

3D Product


Process Analysis


Headache Problems in Casting Production

84

Thermal Balance: Smooth out hot spots, prevent soldering.

Do not over cool any portion of the die, maintain reasonable temperature

Uniformity across die surface (maintain flatness of part).

Begin to shorten cycle times without creating thermal extremes.

Monitor die / cooling line performance

Document die heat-up performance as a function of number of shots

Confirm simulation and solidification studies


Existed Method: Thermal graphics from camera

85

Turn off cooling channel Turn on cooling channel


What is Casting Production?

86

Casting Production is a special module in Cast-Designer to optimize the casting process to achieve the best productivity and cost rate, as well as the product quality.

Casting Production optimize the cooling channel and production cycle, to maintenance a reasonable mould temperature.

Casting Production can make a quick calculation of the production cost based on the optimized cycling time and user cost database. It could be used whatever the quotation stage for price estimation or the production phase for cost control.

Casting Production is fully automatic and very easy to use.

Advance

module


Casting Production: example, gravity die casting

87

• For each iteration, the system will report the optimized result, such as the new mould opening time, mould closing time and total cycling time.

• Only 3 iterations, to reduce the cycling time from 110 sec, to 74 sec and finally 74.2 sec.

020406080

100120

75 58.5 59

33 3

77 7

25

5.5 5.2

to next cycle

Die closing

part ejection

Die opening

Cast-Designer CPI mesh model

Advance

module


Define process layout and sensor list

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Process layout Sensor list Sensor

Advance

module



89

3D PartDFM Check

QuotationPrepare

GatingSystem




Cast-Designer



Cast-Designer Optimizer

90

Integration Optimization and Parametric studies Post processing

GUI

Task manager

Variables Results

Kernel for process management and data transfer –Integration tool

Cast-DesignerOptimizer

Cast-Designer Solvers(Thermal, Flow, Stress, Advance CFD)


Different Applications in Casting Simulation

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02 DOE (Design of Experiments)

To study a process window and its robustness so as to obtain a set of ideal parameters which provide good result inside an user defined goal.

03 Inverse (Curve fitting) From measured temperature, get the

material data or BC to apply to fit the output.

04 Robustness study Stochastic approach to check that

the given process is robust

For example, vary the furnace temperature within the known range to check that the process is robust enough to still give good parts

01 Optimization Optimize a given set of

parameters to achieve the best possible result based on goals to achieve

For example, to identify an ideal gating system, so as to obtain a balance flow to avoid gas entrapment also better shrinkage porosity.


Cast-Designer Optimizer

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Cast-Designer optimizer is the software for multi-criteria nonlinear optimization. The ideal solution for:

Improving performance

Searching for optimal management laws

Identification and verification

Cutting costs

Cast-Designer Optimizer is a unique software package opening up new opportunities for the market of “complex” practical problems.

It is used to improve the performance of complex systems, technical facilities and technological processes and to develop new materials based on a search for their optimal parameters.

The software also enables lower research expenditures and shorter implementation time. The main purpose of the system is to relieve a designer or researcher of the sufficiently complex and very labour-intensive process of searching for optimal system design parameters which simultaneously meet a great number of sometimes controversial requirements.


Parallel Optimization with Multiple Criteria

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Advantages:

• Maximum use of the potential of

multiprocessor system and local network.

• Efficient use of difficult-to-parallelise

applications and computation models

• Solution of complex problems which

have to present time been thought

impracticable to target.

Cast-Designer can support parallel automatic optimization now, this is a breakthrough

technology to reduce the lead time of optimization.

The user can use the same model for parallel automatic optimization, no any special setup but

one switch button. With this technology, the optimization calculation can speed up 5 to 10

times due to the model setup.

More ever, the restart function is also possible in optimization calculation. Means the user

can continue the last optimization run in any time.


Shrinkage Porosity Optimization

94

D1

D2

Objective: optimize the riser diameter to have the best balance of the riser volume and

shrinkage porosity (accept level).



95

V=6360

V=4108

V=1697

V=2187

V: Volume of All Risers



96

V=6360

V=4108

V=1697

V=2187

V: Volume of All Risers

Safe line

www.auto-design-online.com 97

V=6360

V=6901

V=7609

Safe line

Optimized Zoom

V=1697

V=2187

Basic modeling30 min

Optimization setup1 hour

Optimization run

5 hours for 145 runs

CAST-DESIGNER V7.2



98

3D PartDFM Check

QuotationPrepare

GatingSystem




Cast-Designer



Affordable Price

99

Affordable priceThe ROI is very clear. Now, you only spend a little cost like around one mould price and get the high-end design and simulation solution.

Ph.D.

CAE Specialists

Die Designer


Conclusion

100

=

CAST-DESIGNER

3D Part

DFM Check

Quotation

Prepare

Gating

System CAE Analysis

Manufacture

Production

Thank you!

WWW.AUTO-DESIGN-ONLINE.COM

Cast-Designer... Using HDI for riser design 20 Read in the part geometry in 3D CAD data or STL data....

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Transcript of Cast-Designer... Using HDI for riser design 20 Read in the part geometry in 3D CAD data or STL data....