AnyCasting - Software Intro - Die Casting PDF

AnyCasting TM
Advanced Casting Simulation Software
Introduction of
AnyCasting Functions
Die Casting Process
ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 1

TM
AnyCasting
Total Analysis of All Casting System

▶ 3-D Mold Filling Porosity, shrinkage/Solidification, Mold
▶ 3-D Thermal Stress / Micro Structure / Mechanical Properties
Filling Air Porosity
Die
Chill Vent
Pins Slide Core
Cavity
Solidification Shrinkage
Line Channels
Runner
Shot Sleeve
Main Window of AnyCasting System (HPDC) Predict Several Defects (HPDC)

Assembly Control of CAD Data
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
AnyCasting
CATIA UniGraphics
Import
PRO Engineering Solidworks User can use only STL format

System Configuration
Software Structure
AnyCasting Standard AnyCasting Performance
AnyPRE  HPDC/Thixo Module

 LPDC Module
AnySOLVER
 Permanent Mold (Tilt) Module
AnyPOST  Sand Module
AnyMESH - Cast Iron
- Cast Steel
AnyDBASE
 Large Ingot Module
BatchRunner  Investment Module
AnyCasting Extensible Module
 anyTX
 Advanced Material Properties
 Eject Pin Module
 anyPOST Reader

SW Configuration
AnyCasting Work Flow

▶ Input Data & Solving & Observation
Input Data Solving Observation
Fluid
- Modeling File (STL) - Using Multi Core Process - Entrapped Air / Gas
- Oxide
- Temperature
- Velocity
- Leakage
- Meshing - Dramatic Decreased
- Set Casting Condition Solving Time
Solidification
- Final Solidification Area
- Micro / Macro Shrinkage

SW Configuration

Input Data
- Meshing
- Modeling File (STL) - Set TEMP.
- Set HTC
- Set Pouring Temp.
- Set Shot Condition
- Set Channel
- Meshing - Set Cycle Condition
- Set Casting Condition

SW Configuration

Solving
- Using Multi Core Process
- Dramatic Decreased
Solving Time

SW Configuration

Filling Sequence
Observation
Fluid
- Entrapped Air / Gas
- Oxide
- Temperature
- Velocity Temp. Distribution
- Leakage
Sol. Time
Solidification
- Final Solidification Area
- Micro / Macro Shrinkage
Shrinkage
Velocity Oxide
Distribution

Development Roadmap
2005 2010 2013 2015

V2.0 V4.0 V6.0 V6.3
- Oxide / Inclusion - Real Flow - Auto Mesh - Solver Speed Up

- Shot Sleeve - Filter - Quantitative Analysis - Win 10 Support
- Vacuum - Auto Report - Result Combination - Channel Import /
- Advanced Melt Setting - Calculating Properties - Gas Entrapment Export
- Thermal Stress - Multi Language - Advanced Cyclic Setting - Shrinkage Volume
- Core Gas
- Real Shape - Multi Core Process - Enhanced Particle Tracing - Jmat-Pro Import
- Large Ingot - Cast Iron - Advanced Channel - Result Manager
- Centrifugal Casting - Eject Pin - Exothermic Sleeve - Cross Section Save
- Chinese Version - CPU Core Setting - Misrun
- Fluid Rendering
- anyPOST Reader
V3.0 V5.0 V6.1 V6.5
2008 2012 2014 2017

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 Moving
(Free Section)

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
Generation of 21 Mil. Mesh : 3.5 sec Check think sectioned area by using Cross Section

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)

Database System
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
General DB User DB Advanced Material

(add on function)

Import Calculated Thermal Properties of Specific Material
Import Jmat-Pro Calculation Result File

▶ Enable to Import via File without License
▶ Enable to Input Material Properties that are not in Basic Database

Real Flow
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
Scheme of Cut-Cell Method Scheme of

(Sub-Divided Mesh) Porous Media Method
1. Preliminary Calculation
at Staggered Grid
Fluid
Boundary Cell for

Trace Interface Surface Obstacle
2. Pressure Iteration at Embedded Cell

Un-staggered Grid Approach
→ Immersed Cell When Needed
(Porous Media Scheme)
Fluid Cell for Cell Center : uc, vc, wc, Vf, P, T, ρ, Cp, k
Pressure Interpolation
Face Center : uj, vj, wj, Aj

Real Flow Test - Plexiglass-Water Model Experiments
Filling Accuracy Comparison with Plexiglass-water Model

▶ Gravity Die Casting
General FDM Solver Experiment Real Flow Solver

(Porous Media + Cut Cell Media)
Fluid Fills Runner Partially (Experiment & Real Flow)

Filling Flow goes Faster along the bottom of Runner (same)

Real Flow Test - HPDC Partial Shot Experiments
Filling Accuracy Comparison with Partial Shot Experiments

▶ Thin Walled HPDC Products
(movie file)
Partial Shot
Experiments
(movie file)
Filling Flow Partially Fills & Goes Far Faster along Runner & Product, especially Thin Walled HPDC

Calculate Back Flow during Filling
Development of Filling Sequence : Analysis of back flow in LPDC
d 2 h1  dh1  1
=  + PA - P A - m g - m ( h ) ÷
dt 2  dt  m A
i A
Back Mass
acceleration Pressure Gravity Viscosity Velocity
Pressure in Salk
Melt fluctuates by back flow analysis
Melt fluctuation on the gate

Consider Stalk Out after Filling
Development of Filling Sequence : Analysis of back flow in LPDC

▶ Stalk model is used to set the working condition of entity set as stalk
▶ Melt be removed inside of stalk when set time in stalk option
Filling : 100% Stalk Out
Stalk Out Time : time when melt is decompressed
Solid Fraction : standard solidification rate when melt inside stalk is removed
Air Temperature : temperature of air to be filled inside empty stalk after melt has been
removed

Feature of High Pressure Die Casting (HPDC)
Contents
1. Air Pressure Model 5. Eject Pin Model

2. Plunger Model 6. Gravity Tilt Model
3. Vacuum Model 7. Leak Model
4. Gas Entrapment Model 8. Thin wall Product
5. Oxide Model 9. Fluid Rendering
5. Cooling Channel Model 10. Virtual Sensor
6. Eject Pin Model 11. anyPOST Reader

Prediction of Air Porosity
Trace of Entrapped high Pressure Area during Filling

▶ Display entrapped air area (High Pressured Region after filling)
▶ Consider parting line, air vent, back pressure
Modeling Simulation Result Experimental Result
Vent Design
Original air porosity is distributed on
the surface of top area
Change
Vent Design
Vent Design
Modified
air porosity is reduced by

modified vent design

Plunger Model (Shot – Sleeve)
Consider & Optimize Shot – Sleeve Condition
▶ Low / High Speed, Distance & User can set detail shot condition by using multi injection option
▶ User can observe the fluid inside of sleeve during filling
No – Sleeve Case Sleeve Case

(Oxide Distribution) (Oxide Distribution)

Back Pressure
Calculate Back Pressure during Filling
▶ Tracking the pressure / volume of gas(air) each time step during filling
▶ Calculate an emitted weight of gas(air) to vent or parting line
qout
Air
Melt
Entrapped Gas
- Mold modeling is required to consider parting lines
(Pn, ρn)
Inlet - Calculate merge, separation, extinction of entrapped gas

Back Pressure of Entrapped Gas(air) - Preservation of entrapped gas pressure

Validation of Back Pressure
Compare No Back Pressure and Back Pressure
Result shows
entrapped gas
during filling
Result shows
clear filling
pattern
Result shows
entrapped gas
during filling

Effect of Vent & Vacuum
Calculation of Vent & Vacuum Effect during Filling
▶ Vent : specific plane be regarded as open area but melt can not pass selected area
▶ Vacuum : specific plane be regarded as vacuum machine but melt can not pass selected area
Atmosphere or Vacuum (P0, ρ0)

qv
Vvent Escaping Gas (P1, ρ1)
qm
Air
Melt
Entrapped Gas
(Pn, ρn)
- Continuous Out flow : melt can pass to selected area

- Exposed to Atmosphere : set vent
- User-Defined Pressure : set vacuum
Inlet

Test of Vent & Vacuum Effect
Calculation of Vent & Vacuum Effect during Filling
Filling : 32% Filling : 54%

Closed Vent Vacuum
Closed Vent Vacuum
Movie File
Filling : 88% Filling : 99%
Melt Material AC4C
Mold Material FC150
Closed
(Back Pressure)
Vent
Vent Condition
(Exposed to atmosphere)
Vacuum
(User Define : 38mmHg)

Filling Behavior depend on Vacuum Condition
Partial Shot Test under Increasing Vacuum Condition
Vacuum valve
High Vacuum
system
Reaction Shaft Vacuum gating

Support system
Gate
area
Shot - Sleeve

Pressure Behavior depend on Vacuum Condition
Pressure inside of Sleeve under Increasing Vacuum Condition
1200000
No_Vacuum
No Vacuum
Vacuum valve 1000000 Vacuum_100 mmHg
Vacuum _ 250mmHg
system
Vacuum_300 mmHg
Vacuum _ 500mmHg
Reaction Shaft 800000
Vacuum_500 mmHg
Vacuum _ 700mmHg
Support
600000
Pressure (dyne/cm )
2
Vacuum gating
system 400000
200000
0
Gate -200000 700 mmHg

area
-400000
500 mmHg
-600000
-800000 250 mmHg
-1000000
Sensor
Position 0 1 2 3 4 5 6 7 8
Time (sec)

Definition of Gas Entrapment
Tracking the Gas (H, C, O etc..,) in Melt during Filling

Concept of Gas Entrapment
- The gas can be entrapped above the specific pressure
- The amount of a gas entrapment is proportional to the pressure of the gas in contact with a liquid (Henry’s Law)
- Simulation predict distribution and weight(cc/100g) of all gases
Gas Distribution Effect of Releasing Agent

in ADC12 (Al alloy) & Plunger Speed
 Gas always occurs during the simulation

 Calculate the pressure of the melt and the
generated gas.
 The amount of generated gas changes
depending on the temperature of the melt.
Gas Volume (cc/100g)

H2 0.231
N2 0.011
CO2 + H2O 0.038

A, B : water-based
C : oil-based
Total 0.262

Gas Distribution under Variable Runner Design
Observation of Entrapped Gas after Filling
Case 1 Case 2
Case 3 Case 4
Melt A380
Mold H13
680 ℃
Pouring Temp.
Fixed : 180 ℃
Mold Temp.
Moving : 180 ℃
Low / High Speed 0.2 / 3.61 m/sec

Quantitative Analysis
Quantify the Specific Result (Std. Deviation / Max, Min / Average)
Case 1 400mmHg Case 2 300mmHg Case 3 200mmHg
Average Gas Amount Depend on Vacuum Degree
Standard Deviation of Gas Amount Depend on Vacuum Degree

Oxide Distribution during Filling
Definition of Oxide Film in Die Casting
▶ Oxide defects can be defected in the microstructure and on the casting surface
▶ Oxides are formed by direct oxidation in air, by reaction with water vapor or variable elements
Oxide Film
Melt
- Oxide could be found between air and high

temperature liquid metal
- The collision of free surface is only way in

which oxide films can be introduced into liquid
metal

Oxide Distribution during Filling
Validation of Oxide Result
▶ Oxide defects can be defected in the microstructure and on the casting surface
▶ Oxides are formed by direct oxidation in air, by reaction with water vapor or variable elements
Fixed
Entrapped
Oxide Area
Surface Defect Area
Moving
Entrapped
Oxide Area
Surface Defect Area

Consider Cooling Effect close to Real Condition
▶ Advanced Cooling Effect Setting for Super Cool
▶ Close to Real Phenomenon of Cooling Effect
1. Select channel
2. Input channel direction
3. Input variable HTC each
channel section

Consider Cooling Effect close to Real Condition
▶ Advanced Cooling Effect Setting for Super Cool
▶ Close to Real Phenomenon of Cooling Effect
Result General Setting
Result Advanced Setting

Predict a Safety Factor of Eject Pin
Analysis of Eject Pin

▶ Predict of Installed Eject Pin Safety Factor
▶ Confirm Safety Factor through Change a Properties of Eject Pin in Real Time
Value : 1 or more  Safe

lees than 1  Danger
Ejecting Direction

Predict a Safety Factor of Eject Pin
Analysis of Eject Pin

▶ Predict of Installed Eject Pin Safety Factor
▶ Confirm Safety Factor through Change a Properties of Eject Pin in Real Time
W0 sinθ
W0 cosθ
Machine Setting W0
Ejecting Force xxxx. Kg product
Ejecting Direction -X
mold
Center of Cylinder 200,10,1 W
Install Eject Pin

Position 10,45,10
Length 250mm
W = AP (m cos  - sin )
Diameter 12mm
A : contacted surface area

How to install eject pin P : adhesive force(110 ~ 130 kg/㎠)
1) Input coordinate of eject pin μ : friction coefficient (Al : 0.2 ~ 0.3) Consider contacted area between
2) Install by using Mouse click θ : gradient angle (2 degree) cast and mold when ejecting

Predict Where Leak Defect will be Generated
▶ Leak Definition
- The oil, water, etc.., are leaked to the outside due to entrapped air, shrinkage through machining
area, soldering area
▶ Leak Probability
Pi = c0 + c1  Vi + c2  D1
- Vi : Volume of Shrinkage [cc]
- D1 : Shortest Distance from Shrinkage i to Seizing or Machining Part [cm]
(P > 0.X : Danger, 0 < P < 0.X : Caution, P < 0.X : Safety)
- C0, C1, C2 : Coefficient of experimental value
Water, Oil Machining area

Machining Machining area must be
Porosity
make a modeling file (STL) for
(Air, Gas, Shrinkage)
consider machined area after
Soldering casting
area
D1
D2
Shrinkage Defect
(Radius: r, Volume: V) Soldering

Application of Leakage Defect
Consider soldering, shrinkage, machining Red

: Dangerous area
Soldering Shrinkage
Leakage at Oil Feeder
Machining

Change Casting Design for Decrease Leak Defect
Original Design Modified Design
3
1. Big volume area be change
2. Machining area be changed to casting area
3. Additional overflow for emit to air / gas
Change the Design

Change Casting Design for Decrease Leak Defect

Original Design Modified Design
Leakage Possibility : 60 % Leakage Possibility : 1 %

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

Observation of Temp. Graph by using Virtual Sensor
User can Make Temp. Graph at Area of Non-Installed 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

Check the Result on Power Point by using anyPOST Reader
Sharing Results More Easily

▶ 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)

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

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AnyCasting TM

Advanced Casting Simulation Software

Die Casting Process

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

Total Analysis of All Casting System

Filling Air Porosity

Pins Slide Core

Main Window of AnyCasting System (HPDC) Predict Several Defects (HPDC)

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 2

Import & Assemble of 3D CAD/CAM Data

PRO Engineering Solidworks User can use only STL format

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 3

AnyCasting Standard AnyCasting Performance

AnyPRE  HPDC/Thixo Module

AnyCasting Extensible Module

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 4

AnyCasting Work Flow

Input Data Solving Observation

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 5

AnyCasting Work Flow

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 6

AnyCasting Work Flow

- Using Multi Core Process

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 7

AnyCasting Work Flow

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 8

2005 2010 2013 2015

- Oxide / Inclusion - Real Flow - Auto Mesh - Solver Speed Up

V3.0 V5.0 V6.1 V6.5

2008 2012 2014 2017

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 9

Observe Inside of All Entity Parts

AnyPRE Process AnyPOST Process

Show Section Only

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 10

3-clicks is enough for mesh generation!

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 11

Up to 2-times Analysis Speed Improvement

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 12

User can Select 3 Database System

General DB User DB Advanced Material

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 13

Import Jmat-Pro Calculation Result File

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 14

Using Hybrid Flow – Porous Media Method + Cut Cell Method

Scheme of Cut-Cell Method Scheme of

Boundary Cell for

2. Pressure Iteration at Embedded Cell

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 15

Filling Accuracy Comparison with Plexiglass-water Model

General FDM Solver Experiment Real Flow Solver

Fluid Fills Runner Partially (Experiment & Real Flow)

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 16

Filling Accuracy Comparison with Partial Shot Experiments

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 17

Development of Filling Sequence : Analysis of back flow in LPDC

Melt fluctuates by back flow analysis

Melt fluctuation on the gate

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 18

Development of Filling Sequence : Analysis of back flow in LPDC

Filling : 100% Stalk Out

Stalk Out Time : time when melt is decompressed

ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved 19