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User Guide v 4.

1
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! SUGGESTIONS
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Suggestions for Importing Geometry:


Click2Cast only supports STL files. You need to export CAD data (IGES, STEP, PARASOLID) as a STL file using a CAD
tool (a).
Make sure you are satisfied with the geometry before exporting it. You cannot create new geometry or modify existing
geometry in Click2Cast.
Click2Cast only works with a single closed volume, which must contain a part. If the model contains runners, risers, and
overflows, they must form one closed, solid part (b).
Verify the quality of the CAD data before exporting it.

(a) Export CAD data as a STL file. (b) One closed, solid part containing a
filling system and risers.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Suggestions for Meshing:


Remove 3D text in the CAD tool before exporting to STL format.

Avoid strips or negligibly thin volumes, as they may cause problems during meshing.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Suggestions for Running Calculations:


If the calculation stops before the job is complete, please check for the following errors:

Inconsistent units

Inadequate mesh size. It is recommended to use an Element size of at least 3 in areas


with small thickness to obtain accurate results. If the issue persists, try meshing again
using a smaller element size.

The temperature of the material for the part should not be lower than the solidification
temperature.

Insufficient memory. Try meshing again using fewer elements.


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! SETTINGS & OPTIONS


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Config Tools

Configuration Options
Graphics

Graphical configuration:
Fast visualization mode: Models will be drawn faster, but some artifacts may appear.
Safe visualization mode: Models will be drawn slower, but with no artifacts.

Selection lines by software


Drawing Method: Draw the mesh faster or slower.
Vertex Buffer Objects: For Fast visualization mode and Open GL 1.5 or higher.
Vertex arrays: For Open GL 1.1.

Media
Image and video settings.
Settings for animating velocity.

Language
Choose your language.

General
Display/hide the Step tips.
Define the Solidification stop temperature
Get simulation results in H3D format. The results will be saved in the project folder.
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Config Tools

Configuration Options

Material Editor
Create/modify custom materials by changing
the material properties.
New/modified materials will be saved in:
\Documents\solidThinking\c2c\usermaterial
database* **

Create a new material

Rename material
Add row value
Delete material
Delete row value
Apply changes

Save material Show/Hide Graph

* Custom materials will not be deleted when an older version of C2C is uninstalled.
** The newer version of C2C will search for a previously saved material and merge it with the current version of the material.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
About Tools

Click2Cast License Wizard


Please see the solidThinking License Setup
Guide for more information about licensing, or
contact our support team at
support@solidThinking.com.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
About Tools

User_Guide.pdf
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
About System Requirements

Operating Systems:
Windows 7, Windows 8.1, Windows 10
64-bit only

Hardware:
OpenGL graphics card with at least 256 MB of onboard memory.

Memory:
4 GB of RAM (8 GB recommended)
10 GB or more of free hard disk space
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
General Information

The General information window displays


information regarding the current settings for:

Geometry
Mesh
Parameters
Calculation
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General Information

The Step tips guide you through the basic


workflow, giving you advice at each step:
Geometry, Mesh, Parameters, Calculate,
Results, and Report. Continue reading this user
guide for more detailed information.

Select Dont show next time to hide the Step


tips.

To display the Step tips again, go to


Configuration Options, select General for
Info type, and activate the Step tips option.
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View Options

The -/+ buttons allow you to collapse and


expand the mesh and process parameter
options.

Click on the - button if you are using a small


monitor or laptop.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

General Tools

Rotate the model (Shift+left-click)

Pan the model (Shift+right-click)

Display information such as the temperature at


a selected point on the model (press Esc to
Fit all
confirm)

Change the light direction


Zoom (Shift+scroll wheel)

Measure the distance between 2 Define a cutting plane by selecting 2 points


selected points

Display the model in green, blue, gray, or


Display the model as a mesh
orange

Save the model as a GID file Orient the model along the XY, XZ, YZ, or
(C2C project) isometric plane

Take a picture Exit


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! GENERAL WORKFLOW
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Go from opening the model


to analyzing the results
in 5 simple steps.
Open the geometry in STL format Define the ingate Define the process Run the Analyze the
and select additional materials and create the mesh parameters calculations results

1 2 3 4 5
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Step 1 Geometry

Create a new project by importing a STL file.*


(You will find some example files in the C:/Click2Cast/examples/ folder.)

Open an existing Click2Cast project.


The file extension is .gid.

Select a unit of measurement for the model.

* STL is a standard CAD format. Make sure the geometry is a single volume in STL format before importing into Click2Cast.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Step 1 Geometry

Add a new casting component by selecting areas where the component is in contact
with the part. Define the component Type by selecting from Core, Mold, Chiller, or
Sleeve.

Click on these buttons to add/remove selected areas.

Click on these buttons to automatically increase/decrease the selected areas.

Select the component to display.

User the Interior View slider to see inside the geometry so you
can more easily add/remove interior surfaces.
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Step 2 Mesh

Select AUTOMATIC if your model has a predefined ingate. Just


click on the model to locate the ingate.

To add another ingate, select Add Ingate and click on the model.
To remove an ingate, select Delete ingate and select the ingate.

The mesher works on


curved surfaces.

If a radius is detected at
the selected ingate
surface, the mesher can
create an irregular ingate
definition based on the
assigned Element size.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Step 2 Mesh

1. Select ADVANCED to create a virtual ingate.


2. The ingate can be square or circular.
3. Define the size of the ingate.
Height and Width for a square ingate
Radius for a circular ingate
4. Select an Orientation.
5. Select Add Ingate and click on the model to position the ingate. Click again as many
times as you like to add as many new ingates as you want.
Click2Cast uses a parametric solution; if you position the ingate on a curved
surface, the ingate will be projected onto the surface.
The ingate cannot be positioned outside the model or along a sharp edge.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 2 Mesh
Number of Calculated Filling
Elements Time

214.576 1h 16m

69.743 16m 12s

4.282 12s

Enter an Element size and click on Create mesh to generate the mesh.
Click2Cast uses Finite Element Method (FEM) technology to create the mesh.

The Element size determines the accuracy of the mesh. A smaller Element size (and consequently more elements) increases
accuracy, but lengthens the calculation time. A larger Element size (and consequently fewer elements) decreases accuracy, but
shortens the calculation time.
If the Element size is greater than the thickness of the part, the geometry will be distorted and may be impossible to mesh. In this case,
try decreasing the element size and meshing again.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Step 3 Parameters

Choose from the most common casting materials and alloys used in the casting industry. Select the
casting temperature.

Choose from the most common mold materials used in the casting industry. Select the mold
temperature.

The Gravity direction may change depending on the actual position of the mold.

Use the Basic option to perform a quick, general simulation. Just define the Ingate Velocity or the
Filling Time.
Filling Time: Select this option if you have calculated the exact filling time required for your
process. Units must be in seconds.
Ingate Velocity: Define the velocity at the predefined ingate. Units must be in meters by
seconds.
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Step 3 Parameters

Enable the Use Coating option to add a coat of paint to the


mold. Use the drop-down list to choose a type of coating.

Use the Advanced option to simulate a specific casting


process: High Pressure Die Casting, Low Pressure Die Casting,
or Tilt Pouring. See the following pages for information on the
relevant parameters.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Step 3 Parameters

Advanced - High Pressure Die Casting (HPDC)

Define the Gravity direction (the position of the part relative to the mold).

Define the 1st Velocity and the 2nd Velocity if the piston and runner have been drawn.*

Click on Select Node and select a point on the model to define the Velocity phase change point.

*If the piston and runner have not been drawn, use the formulae in this image to
calculate the first and second velocity phase from the first and second piston velocity.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.

Step 3 Parameters

Advanced - Low Pressure Die Casting (LPDC)

Define the Distance from the free surface (vertical distance between the liquid free surface in the
crucible and the mold ingate) to the pressure curve to generate the Time vs. Pressure curve of the
metal displacement system.

Pressure Curve: Time vs. Pressure graph of the metal displacement system. Enter the same data
that was used for the LowP-DieCast Machine in the Pressure curve table, and click the Graph icon
to update the Time vs Pressure graph.
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Step 3 Parameters

Advanced - Gravity Casting (GC)

Filling Time (s)


Select this option if you have calculated the exact filling time required for your process. Units must be in
seconds.
The flow rate will be calculated automatically based on the defined ingate.

Spoon Height (mm)


Select this option if you have manual ladle operators. Enter the pouring height of the ladle with respect to
the mold. Units must be in millimeters.
The flow rate will be calculated automatically based on the defined ingate.

Flow Rate (kg/s)


Select this option if you have an auto pour ladle, bottom pour ladle, stop and rod ladle, etc.
To calculate the flow rate, divide the volume of the poured metal (kilograms) by the filling time (seconds).

Tilt Pouring (see next page)


Investment Casting (see page 29)
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Step 3 Parameters

Advanced - Tilt Pouring

Activate the Tilt Pouring checkbox.

To define the tilting rotation, first select X, Y, or Z to define the axis of rotation, and then pick a point
on the geometry to define the Rotation Point.
The tilting rotation follows the same order as the XYZ coordinate axis; if you select Y as the axis of
rotation, then Z will rotate over X; if you select Z, then X will rotate over Y, and so on.

Enter the Initial angle (e.g., +/-90, +/-45). The final position is the
actual position of the casting (0).

When you define the Rotation time, you are also defining the total filling
time (in seconds).
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Step 3 Parameters

Advanced Investment Casting

Select Investment Casting.

Define the Gravity direction.

Define the Filling Time, Spoon Height, and Flow Rate.

Select the Type of mold material.

Define the Temperature.

Define the Shell Thickness.


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Step 4 Calculate

Select the Analysis type:


Filling, Solidification, or both.

Once 1% of the calculation has completed,


Run the calculation. you can go straight to the next step and
view the results.
Stop the calculation.

Progress bar

When running a solidification analysis only, the starting temperature will be the same throughout the entire part. When
running both filling and solidification analyses, the temperature distribution at the end of the filling analysis will be used as
the starting point for the solidification analysis.
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Step 5 Results Filling

Flow Front shows you how the material behaves as it enters the mold, so you can predict filling
time (the elapsed time is shown in seconds). You can then decide if you need to reposition the
ingate and overflows to avoid air entrapment.

Gray represents liquid material that is in contact with the mold. Red represents liquid material
that is in contact with the air. Click twice to show the flow front behavior as transparent.
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Step 5 Results Filling

Temperature shows you how the temperature changes during the filling process. You can determine the temperature
required for two fronts of material to fuse, and study the risk of cold welding. Click twice to set the maximum and
minimum temperatures.

Velocities represents the filling process using vectors, allowing you to detect turbulences and velocities. Click twice to
change the visualization
mode and set maximum
and minimum values.
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Step 5 Results

TIP:
Select the Scissors icon to cut the mold and see how the
material behaves inside.

Select the Labels icon to display information such as the


temperature, velocity, and material at any point on the part.
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Step 5 Results Filling

Cold Shuts shows in colored areas where two fronts of material meet and what is the temperature
difference. This option is useful for predicting cold unions. Click twice to set the maximum
and minimum values.

Air Entrap. shows in blue the last areas to fill so you can predict where bubbles may form. You can
then reposition the overflows to prevent porosity.
Click twice to show the interior air entrapment.
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Step 5 Results Filling

Mold Erosion shows in color areas where velocity exceeds 35 m/s, where mold degradation is likely
to occur. If no colored area is displayed, mold erosion will be low. Click twice to change the range of
velocities shown.

Filling Time shows the time it takes the material to reach different areas within the part, based on a
color legend. This helps you determine the best way to fill the part.
Click twice to set the maximum and minimum values.
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Step 5 Results Filling

Solid Fraction displays areas where solidification will occur. These multicolored areas will not fill
completely and are therefore prone to shortage of material. Based on the results, you may need to
increase the pressure, increase the velocity, or reduce the filling time to prevent shortage of material.

Blue represents liquid material, areas where there will be no filling issues.

Pressure displays changes in pressure during filling (Pascals).


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Step 5 Results Filling

These buttons toggle between Filling Results and Solidification Results.


The results are available once 1% of the calculation is complete.

Load the solidification analysis.

Refresh the calculation.


Displays the percent calculated and percent loaded, and visualizes this data with a
progress bar.
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Step 5 Results Solidification

Temperature shows changes in temperature during the solidification process. Click twice
to set the maximum and minimum temperatures.
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Step 5 Results Solidification

Liquid Fraction displays the last areas to solidify (liquid material) in red so you can predict
shrinkage porosity.

Click twice to change the solid fraction value, which is set to 0.7 by default (in most cases, this
corresponds to the value at which the liquid stops flowing). In the animation, solidified material
(above 0.7) is transparent, while liquid material (below 0.7) is shown in red. Shrinkage porosity
is more likely to occur in isolated red areas.
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Step 5 Results Solidification

Solidif. Times shows the time required to fill different areas within the part, based on a color legend.
This helps you identify which areas will fill first and predict possible areas of cold welding.

The Niyama criterion function is commonly used by foundries to detect solidification shrinkage
defects. The lower the value, the higher the probability of shrinkage.
Ranges of critical values are:
Steels: 0-1
Cast Irons: 0 - 0.75
Aluminum: 0 - 0.30
Copper Base: 0 - 1.30
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Step 5 Results Solidification

Porosity shows areas where the ratio of voids to solid areas is greater or equal than to the specified
value. Click twice to change the percentage value. Click on Max value to display the maximum
porosity.

Porosity shows shrinkage porosity volumetric values.


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Step 5 Results Solidification

Solidification Modulus is the ratio of the casting volume to the surface area (meters).
This value is needed to use the Riser Designer wizard.

Mold Temperature shows temperature changes in the mold during the solidification process.
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Step 5 Results Solidification

Load the filling analysis.

Refresh the calculation.


Displays the percent calculated and percent loaded, and visualizes this data
with a progress bar.
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Step 5 Results Solidification

The Riser Designer wizards calculates the optimal


size of the a riser based on the casting modulus.

Enter the Casting modulus (meters), which is


used to calculate the dimensions required for the
riser. Then select a Sleeve type: Exothermal
sleeve, Isothermal sleeve, or None.

For results, you can obtain a Diameter and height


from modulus, a Diameter (from the cylinder
height), or a Height (from the base diameter).
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Step 5 Results Graphs

Click the Graph icon to generate a graph.


Click on different points on the geometry or in
a cut and press Esc. A graph is created,
showing the behavior at these points over
time.

Two types of graphs are available:


- Changes in temperature and velocity during
the filling process
- Changes in temperature during the
solidification process

Click on a line in the graph to show the points


that were selected in the geometry.

You can also add points, remove points, change


the colors of the lines, and export the data as a
GRF file.
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Step 5 Results Options

Play

Rewind

Animation control bar

Take a snapshot (.jpg,.png)

Record a video (.gif,.mpeg,.flv)

Open the current folder


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www.solidthinking.com

For more information, please contact


info@click2cast.com

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