ProCAST Simulation

Getting started with ProCAST

Gravity Casting process

DICV-Solo Carrier

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 Time distribution for Activity

ProCAST-Simulation Activity Avg. Time requirement

CAD Geometry Input Simulation Results

Sr.N Part Iteration 2D Mesh 3D Mesh
Correction Parameter Run Time Analysis
o. Name No (1-5 Hrs) (1-3 Hrs)
(1-3 hrs) (1-1.5 Hrs) (12-16 hrs) (1-2 Hrs)

1.Volume
1.Surface Blend 1.Temp.
1.Volume Correction 1. thermal
1 Solo-Carrier L1 2.Sketch addition Correction 2.2D 2.HTC Simulation Run 2.Velocity
3.Flat Planar for vertical 2.2D Correction Correction 3.User Define Time 3.Shrinkage
face 4.Graph
3.3D Mesh

Total Time required for one iteration :- 20 Hrs

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 Technical Information

• Materials and Initial Conditions

– Casting : S.G. 400/18 (1405 °C)
– Core : CBFMS-C (Fine) (35 °C)
– Mold : Green Sand (35 °C)

• Filling
– Pouring Température 1405 °C
– Pouring Time : 16 Sec.
– Ilet Diameter : 40 mm

• Foundry ambience
– Ambient Température : 35 °C

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 Technical Information
Output Results Required:-
CASTING SIMULATION INPUT DATA SHEET Flow Colour Path :-Yes/No
Turbulence of metal flow:-Yes/No
Metal flow length:- Yes/No
Part owner name: Manish Nalawade
Metal material age:-Yes/No
Part name: DICV-Solo Carrier oxides formation in mould:-Yes/No
Iteration No:- L1
Input Parameter
Expected Part started date:- Expected Part End Date:-

Casting Grade:-
TECHNICAL DETAILS
Sr.No. TYPE OF ANALYSIS SELECT Chemical Composition

1 Fluid flow analysis YES/NO Specified

Element
2 Solidification analysis YES/NO
Range/Actual
Carbon %
3 Microstructure analysis YES/NO
Silicon %
Manganese %
Requirement of CAD Model files Copper %
Sr.No. Chromium %
Model SELECT File Type Tin %
1 IGS Sulphur %
Casting Model Mandatory
2
Chill Model YES/No
IGS Phosphorus %
3 IGS
Magnesium %
Riser model YES/No CE %
4 IGS
Sleeve Model YES/No
5
Denser Model YES/No
IGS Total Bunch Weight:- Kg

6 IGS
Pouring time:- Sec
Gating Model YES/No Pouring Temperature:- C
IGS
7 OR Total bunch Model YES/No
Type of Core :-
Note: 1.Pelase keep the 2 mm extra depth of ingate in casting
Type of filter and Size :-
2.Sleeve model give as solid without cut with riser

3.The Filter connection there should not be any radius

4.In bunch model all indiual volume kept separate and do not unite and make one IGS file

5.All IGS files to be share on FTP Server

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Launch - Mesh Application

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 Geometry
CAD

1 Applications Mesh

2 File / Open «casting.x_t »

3 File / Append « sleeve.x_t »

4 File / Append « mold1.x_t »

5 Repair / Check : No
problemes identify

6 Assemble / Check / Assemble All

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2D Mesh

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 2D Mesh

1 Compute volumes 2 Correction of 2D mesh

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2D Mesh quality check

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3D Mesh quality check

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Switch to - Cast Application

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 Process Definition
GRAVITY ORIENTATION

Cast / Gravity Vector/Tilt :

Select +X as gravity direction.

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 Process Definition

MATERIAL MANAGEMENT
Volumes / Edit

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 Process Definition

Interfaces HTC / Edit :

Assign type COINC to the interface between Mold and Core  h = 100
Assign type COINC to the interface between Casting and Core  h = 200
Assign type COINC to the interface between Cast and Mold  h = 300

Typical
Typical values
values for
for hh (Int
(Int HTC
HTC inin W/m
W/m22K)
K)
••Metal
Metal –– metal:
metal: 22 000
000 –– 50
50 000
000
••Metal – sand:
Metal – sand: 500
500 –– 22 000
000
••Sand
Sand –– sand:
sand: 300
300 –– 800
800
Apply and close.
••Solid
Solid –– air:
air: 55 –– 20
20
••Solid
Solid – cooling air:
– cooling air: 100
100 –– 11 000
000
••Solid
Solid –– water:
water: 55 000
000 –– 40
40 000
000

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 Process Definition

Heat Exchange / New Select all the external faces

Boundary
condition : Air
Cooling

Apply and close.

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 Process Definition

Pouring Cup Control Parameter

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 Process Definition

Inlet / New

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 Process Definition

Flow Colour Path Parameter

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 Simulation Parameter Definition

General Parameter

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 Simulation Parameter Definition
Thermal Parameter

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 Simulation Parameter Definition

Flow and Microstructure Parameters

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Simulation Parameter Definition

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Switch to - Viewer Application

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 Flow Analysis

Ingate-3

Ingate-4
Ingate-1

Ingate-2

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 Flow Analysis

Flow velocity Analysis

Air Entrapment Analysis

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 Flow Analysis

Vector Flow velocity Analysis

Vector Flow velocity Analysis

Filling Time Analysis

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 Flow Analysis

Colour Flow Analysis

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Flow Analysis

Colour Flow Analysis

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Thermal Analysis

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 Thermal Analysis
Fraction Solid Analysis

Before

After
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Thermal Analysis

Before

After
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Fraction Solid Analysis
Thermal Analysis

Before

After
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 Thermal Analysis
Fraction Solid Analysis

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 Thermal Analysis

Thermal Modulus Analysis

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 DICV - SOLO CARRIER

Date:- 31.03.16

Casting Weight :- 58.2 kg.

Double cavity :- 116.4 kg.
Bunch Weight :- 215.32 kg.
Yield :- 54.05 %

OLD LAYOUT BEFORE SIMULATION

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 DICV - SOLO CARRIER
Date:- 31.03.16

Casting Weight :- 58.2 kg.

Double cavity :- 116.4 kg.
Bunch Weight :- 155.0 kg.
Yield :- 75.1 %

NEW LAYOUT AFTER SIMULATION

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 Comparison between Old and New
Gating System

SR.NO DESCRIPTION OLD GATING NEW GATING REMARS

SYSTEM SYSTEM

1 YIELD 54.05 % 75.1 Yield improved by 21.05 %

2 GATING SYSTEM 98.92 kg 38.6 Material saved by 60.32 kg

3 FEEDER 8/11 (4 nos.) 6/9 (2 nos.) 2 nos. sleeve saved

4 RING CHILL 1.45 kg(1 nos.) 1.45 kg (1 nos.) Achieved shrinkage level- I
5 FLANGE CHILL -- 0.7 kg(2 nos.) Achieved shrinkage level- I
6 QUARTER CHILL -- 0.48 kg(2 nos.) Achieved shrinkage level -I
7 SECTOR CHILL -- 1.71 kg(2 nos.) Achieved shrinkage level- I

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Thank You !

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