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2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
! SUGGESTIONS
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
(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.
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.
Inconsistent units
The temperature of the material for the part should not be lower than the solidification
temperature.
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.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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* **
Rename material
Add row value
Delete material
Delete row value
Apply changes
* 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
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
Geometry
Mesh
Parameters
Calculation
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
General Information
View Options
General Tools
Save the model as a GID file Orient the model along the XY, XZ, YZ, or
(C2C project) isometric plane
! GENERAL WORKFLOW
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
1 2 3 4 5
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 1 Geometry
* 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.
User the Interior View slider to see inside the geometry so you
can more easily add/remove interior surfaces.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 2 Mesh
To add another ingate, select Add Ingate and click on the model.
To remove an ingate, select Delete ingate and select the ingate.
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
214.576 1h 16m
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 3 Parameters
Step 3 Parameters
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
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 3 Parameters
Step 3 Parameters
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).
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 3 Parameters
Step 4 Calculate
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
Step 5 Results
TIP:
Select the Scissors icon to cut the mold and see how the
material behaves inside.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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.
Temperature shows changes in temperature during the solidification process. Click twice
to set the maximum and minimum temperatures.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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.
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.
2017 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company.
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