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Design Optimization
Design Optimization
CAD Import
Design Verification
Design Optimization
CAD Import
Design Verification
Design Optimization
CAD Import
Design Verification
Design Optimization
Optimization
CAD Import
Traditional Approach
Volume Modulus = Surface Area
New Approach
Thermal Modulus calculated from solidification analysis of naked casting
Horizontal Gating
Vertical Gating
Design Verification
Design Optimization
Some Basic Points SOLIDCast deals with 3D models. This means we need to be aware of the directions X, Y and Z. X and Y are considered HORIZONTAL directions. Z is considered VERTICAL. +Z is up, -Z is down. In SOLIDCast, you create projects. A project consists of models, meshes and simulations. Usually a project refers to one part number, and the various design iterations associated with that part. The steps in the project are shown on the left side of the SOLIDCast screen this is the Project Tree
Enter Dimensions
File Converter
STL File
STL File
Note: A File Converter may be a CAD system (examples: SolidWorks, SolidEdge, ProEngineer) or a viewing/conversion program such as SolidView.
Composite Models
Solid Cylinder Solid of Extrusion Solid of Revolution Solid Cylinder
STL File
Block
Solid of Revolution
Solid of Revolution
1. Start SOLIDCast 2. Select File New Model 3. On the Tool Bar, click Add a shape to the Model 4. Click the down arrow on the Shape Type field. Move to the bottom of the list of Shape Types and select STL File. 5. Click the File button. 6. Locate the STL file to load, select it and click Open 7. Click the Add Shape button. 8. Click Zoom Options on the Tool Bar and select Zoom Full
Questions Whats the difference between ASCII and binary STL files? ASCII files are text files. Binary files are encoded. How can I tell which type of file I have? If you dont know, open the file in Windows WordPad. If you can read it, its ASCII. If not, its binary. What about units Inches and mm? If your system is set to English units, SOLIDCast assumes the STL file is inches. If in metric units, SOLIDCast assumes its mm. Before selecting the file, you can specifically select inches or mm on the Add Shape window. After importing, you can check dimensions just by clicking on a couple of points. If its wrong, delete the shape and re-import.
Questions What do I do if I only have an ACSII STL file? Use the SOLIDCast STL Convert Utility Program to convert the ASCII file to binary.
1. On the Tool Bar, click Add a shape to the Model 2. Click the down arrow on the Shape Type field. Select the type of shape you want to create. 3. Enter the required coordinates and dimensions, and select the material type. 4. Click the Add Shape button.
Questions What if I enter the wrong dimensions, or want to change something later? You can select the shape, and then select Edit Edit Selected Shapes and change the shape parameters. What is the Priority Number? Priority numbers are important ONLY when two shapes of DIFFERENT MATERIAL overlap. The shape with the lowest Priority Number ends up in the overlap region.
Questions What is the difference between Casting Material and Riser Material? They are both casting alloy, and act exactly the same during the simulation. The main difference is that the system will display a different weight summary for each material type, so you can break the total metal weight into the casting and the rigging, to calculate yield. Also, you can specify a different HTC at the riser/mold surfaces and the casting/mold surfaces, in permanent mold simulation, when you use these different material types.
1. First, you can (optionally) set the Snap by selecting Tools, System Parameters, Model & Sim then enter a Snap to Grid dimension. 2. On the Tool Bar, click Add a shape to the Model 3. Click the down arrow on the Shape Type field. Select the type of shape you want to create, either Revolved or Extruded. 4. Start sketching on the screen. 5. Click the check mark on the Tool Bar to close the shape. 6. Enter the shape information in the window. 7. Click Add Shape
1. On the Tool Bar, click Select Shape Mode, which is an arrow pointing to the upper left. 2. Click on any shape in the model. This shape will turn a different color (usually red) to indicate that it is selected. 3. You can select MULTIPLE SHAPES by pressing the Ctrl key when you click on the shapes.
1. Once shapes are selected, then select Edit and Move Selected Shapes. 2. You can enter X, Y or Z distance to move the shape. 3. You can move the shape around using mouse clicks in an orthogonal view. 4. You can move a shape from one Pick Point on a surface to another Pick Point.
1. Once shapes are selected, then select Edit and Copy Selected Shapes. 2. You can perform a Linear Copy operation, which creates one or more copies offset from the original at a given X,Y,Z offset distance or 3. You can perform a Ring Copy, which creates a series of copies, spaced evenly around an axis (for example, every 30 degrees around the Z axis would result in 11 copies of the original shape, plus the original).
1. Once a shape is selected, then select Edit and Edit Selected Shapes. 2. You can alter any shape characteristic which appears in the window.
1. Once shapes are selected, then select Show and Hide Selection. 2. Later, to display hidden shapes again, select Show and Show All.
1. Select Model and then Materials List from the menu. 2. Select the tab labeled Casting 3. Press the From DB button 4. Use the slider bar to move through the list. 5. Select the alloy and click OK 6. If you want to adjust Pouring Temperature, change the temperature listed as Initial Temperature.
1. You will need to know Carbon, Silicon Phosphorus content as well as Casting Modulus and Temperature in the mold. If you dont know the Casting Modulus, use the Riser Design Wizard on the casting shape. 2. Run the Iron Property Calculation (VDG.exe) Utility Program to get % solid and amount of expansion/contraction. 3. In SOLIDCast, select Model Materials List Casting. Select an iron alloy (for example, CI DI Ferr for Ductile Iron). 4. Now select the Curves tab. 5. Click the Ductile Iron button. 6. Enter Carbon & Silicon to generate cooling curves.
7. Click on the Draw Shrk Curve button. 8. Locate the point with the % solid and expansion/contraction from the VDG program. For mold wall expansion, add 1% or 2% contraction. Click on this point and then click Done. 9. Click on Set CF Solid Pt button and move the CFS line to the % solid calculated by the VDG program. 10. To save this, go to the Casting tab, enter a unique name, and click the Add to DB button.
1. Select Model and then Materials List from the menu. 2. Select the tab labeled Mold 3. On the left side are materials in the Database. On the right side are materials to be used in the model. To select materials from the Database, use the slider bar, select the material, then click Add to list. 4. You can add as many materials as you want to the list on the right. SOLIDCast will maintain this list until you change it. 5. To remove a mold material from the list, highlight it and click Remove from list.
Component Files
You can select any or all shapes within a model, and make a Component File. This can be used to create a library of standard shapes (like risers, or gating components, or chills) so you dont have to recreate these multiple times. This can also be used to make a file of a complete casting model, to transfer to another computer. Component Files contain both the geometry and the material properties of the selected shapes.
1. Select the shapes you want to make a Component File out of or select Edit Select All Shapes to get the whole model. 2. Select Model Export Selection and enter a name for the Component File. 3. This will create a file with an extension of .mdc which contains the shape(s). 4. To use this on another model, select Model Import SOLIDCast 5.x Component and then select the file. This will bring these shapes into the new model.
Planes of Symmetry
Planes of Symmetry can be used to section a SYMMETRICAL MODEL along center lines. This allows you to simulate one-half or one-quarter of the casting to save time. Later, you can use the Mirror function to mirror the data back into the portions of the model which were not simulated (this step is optional).
1. Select Model Options Planes of Symmetry 2. Select the Plane you want to activate (lower or upper X, Y or Z) 3. Enter the location (if its not 0) 4. Press the Activate button. 5. Meshing and simulation will occur only on those portions of the model which are not cut off by the Planes of Symmetry. 6. After running the simulation, if you want to mirror results, select Simulation Mirror.
Filling Simulation
SOLIDCast will perform a simple filling simulation which shows progressive temperature loss of the liquid metal during filling of the cavity. You need to specify the Fill Time (or calculate it with the Gating Design Wizard) and place Fill Material at the entry points for the liquid metal. For a more advanced fill calculation which shows temperature and velocity using true CFD fluid simulation, see the FLOWCast optional module.
Cloning a Model
If you want to make a copy of a model, for the purpose of making a change and running a new simulation, use the Clone Model feature. This creates a duplicate model which you can edit and change.
1. On the Project Tree, select the model you want to clone. 2. Select File Clone Model. 3. A new model will be created.
Meshing a Model
Meshing is required before running any simulation. This breaks the model down into small cubical elements.
1. Select Model and then Create Mesh from the menu. 2. Select Node Size or Number of Nodes. 3. Select Type of Mold. 4. Select Mold Material. 5. Select Mold Thickness. 6. Select Open Top or Closed Top. 7. Click OK.
Weight Calculation
After meshing, the system will display weights of all materials.
1. Select the Mesh entry on the Project Tree. 2. From the menu, select Weights 3. A table of weights will be displayed.
Running a Simulation
1. Highlight the mesh on the Project Tree (the list on the left side of the SOLIDCast screen). 2. From the menu, select Mesh and then Start Simulation 3. To run a simulation under normal conditions, press OK.
Sand Castings
Normally, we neglect internal (material/material) HTCs when performing sand casting simulation In the Materials List, select the HT Coefficients tab. Make sure the check box labeled Use Internal HT Coefficients is blank. For the External HT Coefficient, we normally use a value of 1.5 When meshing, normally we select a Rectangular Mold.
Select only as much sand thickness as you need to absorb the heat (1-2 for smaller castings, 5-6 for large castings) Use Open Top if you have open risers, use Closed Top if you have blind risers
Investment Castings
Select Investment Shell for your mold material. Set the Initial Temperature of the shell to your Preheat Temperature. To create the shell, you have two options: 1 When meshing, select Shell Mold Type 2 Use the Shell Maker utility program to create an STL file representing the shell
After meshing, be sure to use View Factor calculator to account for radiant heat exchange. Select Mesh View Factor Calculation.
Why use the Shell Maker? If you have things which are external to the shell such as insulating wrap on the gating, or a bed of vermiculite in which the shell is submerged, creating a shell as part of the model makes it easier to accurately create the model. To use ShellMaker, you must have an STL file of the casting AND the gating. If parts of the model were created with SOLIDCast basic shapes, you can create an STL file using the STL from Model Utility Program.
From the Tools, and select the Shell Maker Utility Program. Specify the STL file and the surface quality. This will create an STL file representing the shell. Now, in SOLIDCast select Add a Shape, select STL and select the shell file. Designate it as Shell Material, and give it a large Priority Number (like 8 or 9). Later when you mesh, select the None option for Mold Type (you already have a mold as part of the model).
Make sure that Internal HT Coefficients are turned ON (in Materials List, go to the HT Coefficient tab and click Use Internal HT Coefficients) Specify an HTC for each actual (physical) interface in the model. If two materials are in contact, there should be an HTC specified for the surface between them. If the mold is rectangular in shape, you can use the Rectangular Mold option in meshing. If you want a specific mold shape, that should be created as part of the model, then select None under Mold Type in meshing.
Make gates and risers out of Riser Material, so that you can specify a different HTC at those surfaces than at the casting surface. If you cant separate the gates and risers (if they are all one STL file) you can make two types of mold material, say Steel1 and Steel2. Make the mold of Steel1, and make inserts around the gates and risers using Steel2, then set up the HTCs accordingly. Between Steel1 and Steel2, use a very high HTC (say, 5000) which will thermally join these into one material.
Mesh twice once with fewer nodes (call this Coarse and once with more nodes (call this Fine). Ratio of nodes may be anywhere from 1:4 to 1:10. When you run the simulation, specify Permanent Mold as the Type, and select the Coarse mesh as the Warmup mesh. If you have FLOWCast installed, you can select which filling algorithm to use for the warmup cycles and for the final cycle.
For aluminum permanent mold castings, we recommend using the $HTRED.410 file in the SOLIDCast folder. This is a text file containing the number 0.30. This reduces the metal/mold HTC by 70% at the solidus point, per research performed by Dr. Sciama at Pechiney.
1. Double-click the simulation on the Project Tree (the list on the left side of the SOLIDCast screen). 2. The Simulation Status window will appear. Close this window. 3. To plot results, click Simulation on the menu. Various options will appear.
Plotting Options
Iso-Surface Plot: Plots one value as a 3D surface inside a transparent casting. Cut Plane Plot: Plots on a 2D plane cut through the casting CastPic Plot: Makes a 3D image of the casting, with data indicated by color mapping. CastScan Movies: Makes movie (AVI) files using multiple, multi-colored iso-surfaces within the casting.
Solidification Pattern
Solidification Pattern
Solidification Pattern
Movie-Making Options
Iso-Surface Movie: Makes a movie of progressive values of Iso-Surface plots. Cut Plane Movie: Makes of movie of progressive values on a 2D cut plane. CastPic Movie: Makes a 3D movie image of the casting, with data indicated by color mapping. CastScan Movies: Progressive: Movie of progressive values of a data item (usually progressive solidification) Rotating: Rotating movie showing results (usually shrinkage defects)
Chvorinovs Rule:
t = B (V/A)2
t = Time to complete solidification B = Mold Constant V = Volume of a section of the casting A = Surface area of the same section of the casting
Increasing Modulus
Lowest Modulus
Highest Modulus
1. Import a 3D model of the casting. 2. Select alloy and mold materials. 3. You MAY elect to place gates to take filling into account. 4. Run a simulation of the casting with no risers. 5. Double-click the simulation on the Project Tree (the list on the left side of the SOLIDCast screen). 6. The Simulation Status window will appear. Close this window. 7. Select the Riser Design Wizard from the menu.
Using SOLIDCast, the typical approach to process design for a new casting is to allow the system to analyze a casting without risers and determine the best suggested design for risering. This is done with the SOLIDCast Riser Design Wizard.
Using the Wizard approach, we first perform a simulation of just the casting, filled through the gates but with no risers. The results of this simulation appear as follows:
Now, we run the Riser Design Wizard, which takes the results of this simulation and suggests what risers are required.
SOLIDCast has determined that 3 risers are required for this casting
SOLIDCast then shows us each of the feeding areas within this casting that have been identified.
Feeding Area 1
Feeding Area 2
Feeding Area 3
Next, SOLIDCast shows us where the optimum point of attachment for a riser would be in each of these three areas. This point is the spot in each area which has the highest Section Modulus.
Finally, SOLIDCast suggests an appropriate size for each riser. This calculation is based on both Section Modulus (volume/surface area ratios) and required feed metal volume for each feed area.
Now, we add the suggested risers at the suggested locations to the SOLIDCast model.
V =
2gH
V =
2gH
Flow Rate (in3/sec) = Velocity (in/sec) X Area (in2) Or Area = Flow Rate Velocity
1. Run a simulation of the casting with no risers. 2. Double-click the simulation on the Project Tree (the list on the left side of the SOLIDCast screen). 3. The Simulation Status window will appear. Close this window. 4. Select the Gating Design Wizard from the menu.
The SOLIDCast System also includes a program called the Gating Design Wizard. This function analyzes the casting and alloy selected, calculates weight of poured metal, suggests an Optimum Fill Time for the casting, and then details sizes of sprues, runners and gates for best filling.
First, we specify the class of alloy we're pouring (in this case, Aluminum Alloy) Next, the system calculates Pour Weight for us. Then, we describe the Critical (thinnest) section thickness. And finally, the system tells us the Optimum Fill Time for this casting (in this case, about 20 sec.)
The next step is to describe the sprue height and the location of the gating relative to the casting.
This allows the system to calculate an Effective Sprue Height to use for gating calculations.
Now, since we have two sprues, well divide the weight in half for each sprue and calculate the associated gating (35 lbs of metal will go down each sprue).
The gating ratio (Sprue:Runner:Gate) can be specified here. The ratio 1:4:4 is recommended by AFS for most nonpressurized systems.
Dimensions at top and bottom of the first sprue are given here.
Dimensions of the runner prior to the first gate, and dimensions of that gate, are given here.
Dimensions of the next section of the runner, and the second gate, are given here. This ensures adequate and even flow to both gates.
Now we consider the second sprue, runner and gate. Dimensions of the second sprue are given here.
And dimensions of the runner and single gate are given here.
Now, within a few minutes, we have calculated all of the dimensional data that we need in order to design the gating for this casting. Lets see how this would look on the final model
Gate: 1 x .642
Now, with the process design as provided by the SOLIDCast Riser Design Wizard and the SOLIDCast Gating Design Wizard, we can run a simulation of the casting process using SOLIDCast to verify the results of the design.
The casting has been produced with no internal porosity in this section.
And now we examine the casting with a horizontal section showing progression of solidification:
With an X-Ray view we can see all internal areas of the casting at one time, to determine that there is no porosity anywhere within the casting.
The result: By using the SOLIDCast process design tools, we have very easily and quickly produced a design for production of this casting which will result in a very sound cast part.
Another Example of using the Riser Design and Gating Design Wizards:
A quick look at a new casting.
Casting Design
The Gating Design Wizard estimates a Fill Time of 78 seconds for this casting
Once number of gates and sprue and runner locations are established, the Gating Design Wizard can be used to calculate proper size for sprues, runners and gates for correct filling of the casting cavity.
Using FLOWCast
FLOWCast assumes that metal flows in perpendicular to Fill Material surfaces. Therefore, you should avoid plunging Fill Material into the top of a sprue:
Right
Wrong
Using FLOWCast
There are two ways to start FLOWCast. Method 1: Use Mesh Start FLOWCast
This loads FLOWCast. You then select settings and start the flow simulation manually.
This is the FLOWCast main screen. You can adjust the display from this screen. To set the steps for saving data, click the Filling tab.
This allows you to set the increment for saving ALL data (temperature and velocity) and also just temperature data, which creates a smaller output file.
Here weve set the increment for saving temperature data to 1%. This will allow us to create a video file later on using 100 frames or pictures.
FLOWCast allows you to select either a FULL CFD solution or a Quick solution. When the hourglass button is depressed, this indicates youve selected the Quick solution.
The Status tab shows data sets saved for FULL data, and is also where you go to create animation files of temperature, velocity and pressure after the simulation is complete.
The Anim tab shows sets of saved temperature data, and is also where you go to create movies showing temperature when the simulation is complete.
The Pathlines tab allows you to turn on or off the tracks of virtual particles which are released into the incoming metal at every 10% increment of fill.
Using FLOWCast
Q: How do I use results of a FLOWCast simulation as the start of a SOLIDCast simulation? If youve run FLOWCast using the Mesh Start FLOWCast option, just start a simulation using Mesh Start Simulation and pick SOLIDCast as the Fill Algorithm:
Using FLOWCast
If you want to run FLOWCast and then SOLIDCast automatically, use Method 2:
First, select Mesh Start Simulation Then specify the FLOWCast Algorithm (Full or Quick) you want to use
Velocity Vectors are plotted on sectional planes cut through the model. To set up plotting of Velocity Vectors, we first need to select Velocity as the item to plot.
From the Settings menu we can select the color for the Velocity Vectors
To turn on vector plotting, we select a Cutting Plane (in this case the X-Z Plane) and ask the system to Display Veloc Vectors on Plane.
Velocity Vectors show the direction of flow of metal at every point on the cutting plane
showing flow streams, vortices and areas of high and low velocity.
Particle Tracks Particle tracks shows the path of simulated particles released into the incoming stream at specific intervals.
Particle tracks are turned on by selecting the Pathlines tab. Color, thickness and number of tracks can be controlled with the Settings menu.
At 20% full
At 50% full
And at 80% full. Particle tracks can also be included in movie (AVI) files.
A Third Example of Using the Riser Design and Gating Design Wizards:
Designing for multi-cavity production
Using SOLIDCast and FLOWCast software, we will develop a design for the rigging and production of this 356 aluminum alloy casting. The first step involves consideration of the casting geometry, without gates or risers.
Using the Riser Design Wizard in SOLIDCast as a starting point, we analyze this shape to determine the Modulus* of the casting. Modulus is a predictor of the order of solidification of various parts of the casting, and can be used to indicate the best attachment points for gates and risers, as well as appropriate sizes for risers.
*Note: The traditional Modulus used in casting design is defined as the ratio of Volume:Surface Area. SOLIDCast uses a Thermal Modulus which is more accurate than traditional V/SA analysis.
Point of maximum Modulus. This is the last point to freeze, and the best place to attach a riser.
The Riser Design Wizard can analyze the patterns of Modulus values within a casting and make recommendations as to how many risers are required, where they should be placed, and what size they should be.
By analyzing patterns within the casting, the Wizard tells us that three risers would be the optimal design.
Next, by using an X-ray view of the casting, we can see where these highmodulus areas are in the casting. In theory, each of these areas should be fed by its own riser.
The next series of views shows the location suggested by SOLIDCast as the best attachment point for the main riser, considering the point of highest modulus within the casting.
Now, the Riser Design Wizard is able to recommend riser sizes for each of these areas. Riser size is determined by consideration of Modulus (the Modulus of the riser should be greater than the Modulus of the casting) and volume (the volume of the riser must be sufficient to provide feed metal to compensate for the contraction of the alloy during liquid cooling and solidification).
Here, the required riser size is given as 2 diameter X 5 high. The volume requirement controls. This is for the main riser for one casting.
Assuming that we might feed two castings with a common riser, we can adjust riser dimensions to provide enough feed metal for two castings.
Doing this, required riser size to feed (2) castings is 2.5 diameter X 6 high.
Now we can ask the system to size the smaller, secondary risers, as follows:
Next, the Gating Design Wizard can give us a suggested Optimal Fill Time and sizes for sprue, runners and gates.
Calculating a Pour Weight for (4) castings per mold, and taking into account the Critical Wall Thickness of 0.217 in the casting, the Gating Design Wizard suggests an Optimal Fill Time of 8.7 seconds.
The Wizard tells us we should have a sprue that is .897 diameter (weve assumed a round straight sprue here).
Using this information, we can create an initial gating and riser design for production of this casting in a 4-on mold.
What happened to the secondary risers 1 and 2? In our initial design, we will test to see if the temperature distribution due to filling through the main riser will be enough to overcome the need for secondary risers, by encouraging directional solidification into the large riser. If not, well add them later or we could try chilling those areas instead.
The next step is to run a simulation of this casting, using the initial design. This will involve using FLOWCast to model the flow of the liquid into the casting, and SOLIDCast to model solidification and shrinkage formation. This will allow us to evaluate this design and determine whether any further modifications are necessary.
FLOWCast is a flow simulation module which models the filling of the gating and mold cavity. FLOWCast models progressive temperature and velocity of the liquid metal.
The following series shows progressive temperature of the liquid metal during filling.
FLOWCast can also show flow pathlines, or particle trace lines. This helps to visualize the flow of the metal and determine whether any excessive vortexing or turbulence may be occurring. This can also be used to predict the likely end location of foreign particles (oxides or dirt) entrained in the metal stream.
Flow Pathlines
FLOWCast can also show velocity of the liquid metal at any point in the liquid.
FLOWCast can also show pressure of the liquid metal at any point in the liquid.
FLOWCast is used to visualize how the gating will function, and how the mold will fill. Flow-related defects such as misruns or cold shuts can be identified. It also provides the most realistic temperature distribution in the casting and mold for a subsequent solidification analysis. In this case, the flow sequence looks good. Now lets progress on to analysis of the solidification of the casting.
SOLIDCast is used to predict the cooling and solidification of the casting after filling, as well as formation of any shrinkage (macroporosity or microporosity).
Here we see the predicted final temperature distribution in the casting, at the end of solidification.
This shows a good temperature gradient from the far side of the casting back into the risers.
This shows a good pattern of directional solidification out of the castings and into the risers.
X-Ray View
X-Ray View
Conclusion By using the gating and risers as suggested by the Gating and Riser Design Wizards, we were able to design the process for this casting very rapidly. By using FLOWCast and SOLIDCast, we were able to verify through simulation that this design should produce a sound casting.
Casting Analysis
737305 INSERT
9-April-2004
Feeder Location 1
Feeder Location 2
Design #1
Progressive Solidification
Design #2
Progressive Solidification
Timing Data CFD Flow Simulation: 111 Minutes Solidification Simulation: 13 Minutes
I select a 4 CE gray iron as the Casting Alloy. I have adjusted the pour temperature to about 70 degrees below the 2550F temperature you gave me, because we are initially going to simulate the iron already in the mold and a 70F temperature drop is a typical estimate for the loss from filling.
And make sure that Internal HT Coefficients are not turned on, and the External HT Coefficient is set to about 1.5.
Now we mesh the model with a relatively coarse mesh 500,000 Nodes with 3 of sand all around.
When the simulation is done, we double-click on Simulation on the Project Tree, which displays the Simulation Status window. We close this window.
Then we select Simulation Riser Design Wizard. All we are doing at this point is calculating the modulus of the casting.
In the Riser Design Wizard, we select Calculate and Display Casting Modulus and press Next.
On this window we can see the maximum value of modulus, which is 1.215. This is the casting modulus. Thats all we need for the moment, so we cancel this plot and close the Riser Design Wizard.
We also need the casting weight, so we select Mesh and Weights from the menu.
And we see that the weight of the casting is about 812 pounds.
Here I have assumed a carbon content of 3.4%, silicon 1.8% and P of 0.02%. We fill in the casting modulus as 1.215 (calculated previously) and for Temperature in the Mold we enter 2480. Pressing the Calculate button, we see that the Shrinkage Time is 41.88% and the amount of contraction is 2.19%. Next, we press the Riser Design button.
This brings up the new Iron Casting Riser Design window. We fill in the weight of 812 lbs, set the amount of mold dilation to 1% (for green sand), assume a side sand riser and set the H:D ratio to 1.5.
Now, pressing Calculate, we see the required sand riser size is about 8.4D x 12.6H. Also note that the Neck Modulus is .786.
Closing the Iron Casting Riser Design window, we now go back to the Simulation Riser Design Wizard function. Now that we know the neck modulus, we want to see if there is a single feeding area or multiple feeding areas in this casting, using the neck modulus as a guide.
In the Riser Design Wizard, again we select Calculate and Display Casting Modulus and press Next.
Now on the plot parameters, we enter the neck modulus which is 0.786 into the Plot This Value field. Then we press OK to plot this value.
This plot shows that there is a SINGLE FEEDING ZONE in this casting, based on the neck modulus. This means we should use a single riser on this casting.
This is what a sand riser might look like, based on the dimensions as calculated with the Iron Casting Riser Design program.
Now we want to know what size sprue and gate to design for this casting. We select Simulation Gating Design Wizard, select Horizontal Gating, enter an estimated pouring weight of 1200 lbs., section thickness of 3.2 inches and press Calc. Fill Time. This gives us a calculated Optimal Fill Time of 53 seconds.
Here we make some assumptions about sprue height and specify a gating ratio of 4:8:3 (pressurized).
The program tells us that the top sprue diameter should be about 3.5 and the bottom diameter about 2.1.
Now we design a gate. The best configuration is to gate into the riser, and to keep a 1:5 ratio of H:W on the gate so that the gate freezes quickly enough. The program calculates a gate size of 0.5 x 5.3 for this condition.
Adding this simple gating system to the model, we end up with a system that looks like this.
Whats left? We might be able to reduce the size of the risers and still produce a sound casting, thus improving yield. This can be done by testing a few smaller riser designs and running new simulations or we could use the OPTICast module and have the system automatically find the best riser design which produces a sound casting while maximizing yield.
How do we know that optimum process designs are actually being achieved?
Revised Design
Acceptable? Done
A new paradigm
Revised Design
Acceptable? Done
Optimizing Engine
What is Optimization?
Optimization is a mathematical method for finding the best solution to a given problem. Automates the search for a design solution Frees the engineers time Provides a more thorough and repeatable design process.
Design Variables
These are elements that are allowed to vary when the computer is searching for an optimum process design. Examples: Height and diameter of a feeder (riser) Size of a feature on the casting Pouring temperature Shell preheat temperature
Constraints
A constraint is some aspect of a design that determines whether that design is acceptable or not. Typical Constraints: Macroporosity Level Microporosity Level Yield Percentage Minimum Cooling Rate Minimum Thermal Gradient
Examine Results
No/Yes
DONE
Optimization allows us to take an initial process design and, from that design, find the OPTIMUM design which will result in maximum part quality and minimum part cost.
Simulation of current riser shows adequate size and mass to feed the casting properly.
Question: Can the weight of the riser be reduced, and yet still provide adequate feeding to the casting? We can answer this question using mathematical optimization.
The OPTICast system combines the SOLIDCast casting simulation package from Finite Solutions, Inc. with HyperOpt Optimization from Altair Engineering.
In order to perform optimization on this riser design, we need to define three parameters: Design Variables Constraints Objective Function
Design Variables are any aspects of the design that we will allow the optimizer to vary during the optimization run.
Here we have selected the riser as a Design Variable. Its Height and Diameter will be allowed to vary independently.
A Constraint is an output which determines whether a design is acceptable. Here we set Casting Porosity as a constraint. Porosity is measured by considering the minimum local material density in the casting. The constraint value is set to 1.0, which indicates no casting porosity allowed.
The Objective Function is a simulation output which measures the end result we are trying to achieve.
For purposes of this optimization, we define a yield number such that Casting Weight Yield = Casting + Riser Weight The Objective Function is the maximization of this number, which results in minimum riser weight.
Examine Results
No/Yes
DONE
Optimization Results The riser design optimization was complete after 26 simulations. These were run completely automatically. Total processing time was 2 hr. 56 min. on a 1.0 GHz PC.
This chart shows the progressive value of the Yield function over 26 simulations. Its value started at 0.60 and ended at 0.72.
This chart shows simulated porosity in the casting. A value of 1.0 represents a completely sound casting. Final value of 0.9995 is within allowable limits.
A plot of the vertical scale of the riser. The final riser design is 13.1% taller than the current riser.
A plot of the horizontal scale (diameter) of the riser. The final riser design is smaller (72%) in diameter than the current riser.
Simulation of the optimized riser design shows adequate size and mass to feed the casting properly.
Weight Reduction
In this case, we start with Design Iteration #7, which produced a shrink-free casting.
This design used two small wedge shapes under the gates to help feed metal into the heavy section of the casting.
The first step is to select Design Variables. These are features of the gating that are allowed to vary in size.
Here weve selected the horizontal feeder bar as Design Variable #1.
Were specified that ONLY the horizontal dimensions of the pour cup can vary; its height stays constant.
The gates height is held constant, but its width is allowed to vary.
The other gate is linked to the first gate, which means that the two gates will always be the same shape.
Now we need to apply a Constraint. This is an OUTPUT VALUE from each simulation which determines whether the results are acceptable or not. In this case, our constraint is that the casting must be free of shrinkage. Any design which results in shrinkage in the casting will be discarded.
We measure shrinkage as Material Density. A value of 1 means a perfectly sound casting, so we set the Constraint Value to 1.
Finally, we select an Objective Function. This is an OUTPUT VALUE that we are trying to either maximize of minimize. In this case, our objective function will be to Maximize the Yield. This means that the maximum yield (i.e., the minimum amount of poured metal weight) which produces a shrink-free casting will be found.
This is done just by selecting Yield Maximization from a list of Objective Functions.
At this point, we start the optimization running. This is a TOTALLY AUTOMATIC process. OPTICast will run a series of simulations, varying the gate design until the yield is maximized and the casting is shrink-free. This process can be illustrated as follows:
Run a Simulation
Extract Results
No/Yes
DONE
In effect, the computer is redesigning this gating system ON ITS OWN, using the rules and guidelines that we set up.
This chart shows the vertical scale factor for the feeder.
This shows the horizontal scale factor for the pour cup.
And, finally,this chart shows the horizontal scale factor for the gates.
So, how does the optimized design compare with the original gating design?
Solidification Pattern
Hot Spots
No Hot Spots
Original Gating
Optimized Gating
Shrinkage Prediction
Shrinkage in Casting
No Shrinkage in Casting
Original Gating
Optimized Gating
Original Gating
Optimized Gating
Final Results 1. Pour weight reduced 34.7 Lbs. per casting 2. Shrinkage eliminated from casting 3. Annual savings: $17,000 4. Energy savings: 7,000 KWH/yr
Utilities Menu
Allows you to convert an ASCII STL file to a Binary STL file so that it can be loaded into SOLIDCast as a model shape.
This program accepts an STL file as input, and creates a new STL file as output which represents a shell of a constant thickness around the first STL file. This shell shape can then be brought into the SOLIDCast model as a model shape.
Custom Formula
Allows you to create a customized formula for calculation and plotting from SOLIDCast results. For example, in aluminum alloys a formula for Dendrite Arm Spacing (DAS) in microns is: DAS = 35 (ts-tl) 0.333 and in Steel a formula is: DAS = 100 (ts-tl) 0.41 Both of these formulae can be entered using Custom Formula, and plotted using Custom-High.
Allows you to capture time/temperature data from an unlimited number of points within a model.
This utility allows most of the metal in a tilt pour FLOWCast simulation to enter the mold at a given percent of tilt. For example, if the mold tilts through 90 degrees during filling, and the user specifies 50% as the completion point, then most of the liquid metal will have entered the mold during the first 45 degrees of tilting.
Filter Shape
This utility helps you to create an STL file consisting of a rectangular block with cylindrical holes. This object, when added to a model and given ceramic thermal properties, can be used to simulate a filter.
HTC Calculator
This utility helps to calculate the appropriate Heat Transfer Coefficients to use for various situations. Calculations are included for:
Air and water cooling channels Natural and forced convection Radiation Mold coatings
Allows you to calculate % contraction/expansion and CFS point for cast iron, based on the German Iron Society VDG Nomograms and the charts developed by Karsay. This utility also performs risering calculations for cast irons, as demonstrated in the following slides.
Design of risers for Grey Iron and Ductile Iron castings involves one primary consideration above all else:
The solidification of iron castings (ductile, or nodular, iron and gray iron) is unique among cast metals, due to the precipitation of graphite as the iron solidifies. The graphite takes various forms depending on the type of iron. For example, in ductile iron (nodular iron), the graphite is primarily spheroidal, which gives the iron its characteristic ductility since the spheroids tend to reduce localized stresses under load.
While in gray iron, the graphite tends to be in the shape of flakes, which results in gray irons great compressive stress but relatively low tensile stress.
And in compacted graphite iron, the structure and properties tend to be somewhat intermediate.
The precipitation of graphite during solidification causes some expansion to occur, because the graphite is much less dense than the surrounding iron. Therefore, we have several forces at work. The liquid iron tends to contract as do almost all liquids when cooled. During solidification, the austenitic iron also contracts as do most metals upon solidification. However, the precipitating graphite causes an expansion pressure which can be used to our advantage if the feeding system is properly designed.
No matter which type of cast iron we are pouring, the secret of good design is to provide a feeding system to compensate for the liquid shrinkage and then allow the expansion (due to carbon precipitation) to provide enough pressure to produce a sound casting. There are some differences in expansion pressure between ductile iron and grey iron as shown in the following chart:
Regardless of the type of iron casting we are designing, there are a set of basic procedures that can be followed which will help us to ensure high-quality, sound iron castings, using the SOLIDCast Simulation System. These procedures will help to minimize the number of sample castings required, reduce lead times to get into production, and result in consistent-quality castings which will make our customers happy and our foundry more profitable.
Step 1 To begin analyzing a casting in SOLIDCast for the purpose of riser design, we initially run a simulation of just the casting, surrounded by mold material, without gates or risers.
Step 2 We then run the SOLIDCast Riser Design Wizard and select "Calculate and Display Casting Modulus" to find out the maximum modulus of the casting.
Step 3 We next run the SOLIDCast Cast Iron Property Calculator program to calculate the Shrinkage Time (ST) and net Percent Expansion (+) or Contraction (-) of the iron based on chemistry, modulus and temperature in the mold. This is based on the VDG Nomograms and Karsay charts for iron properties.
Step 4 This gives us the net expansion of the iron considering only the metal, without taking into account the dilation of the mold. For actual feeding requirement, we must estimate mold dilation which might vary from less than 0.5% for chemically-bonded molds to more than 2% for loose green sand molds.
Step 5 Rule: Recommended practice would be to use a "hot" riser, i.e., to gate into the riser if using a side riser so that the amount of heat in the riser, and its ability to provide feed metal, is maximized. For top risers, since it is difficult to gate into these, we would typically recommend a sleeve (either exothermic or insulating) to retain the heat.
Step 6 The proportion of liquid metal that can be supplied by a riser can be estimated by knowing its condition. For example, a hot side riser can typically provide about 20% of its metal for feeding, while a typical cold riser might provide around 14% of its metal. A sleeved riser can provide anywhere from 33% to 35% depending on its condition. Exothermic mini-risers have been known to provide up to 70% of their metal for feeding.
Step 7 The formula relating the available volume of metal in a riser to the volume of the casting can be expressed as: Vf = ______ Vc * S x
(Where Vf = Riser Volume, Vc = Casting Volume, S = Feeding Requirement (including Mold Dilation), and x = Proportion of Liquid Metal Removed from Riser)
and from this the diameter of the riser can be calculated if an assumption of riser Height:Diameter is made.
Step 8
The riser neck should be sized so that its modulus guarantees that it will freeze at the point that the liquid shrinkage is done and any subsequent expansion will be controlled and contained within the casting to prevent shrinkage porosity formation. This can be accomplished by using the following formula: Mn = ST/100 * Mc Where Mn = Modulus of the Neck, ST = Shrinkage Time, and Mc = Modulus of the Casting.
Step 9
Also, in order for the riser to provide sufficient liquid melt during the shrinkage period, its modulus should be 20% greater than the neck modulus, which means the riser size should satisfy the equation: Mr = 1.2 Mn or Mr = 1.2 ST/100 Mc
So that if the riser is sized to satisfy the liquid feeding requirement but it does not satisfy this modulus requirement, its size must be increased to satisfy this modulus requirement.
Step 10 If the riser is close enough to the casting so that mold heatup between the casting and riser can be taken into account, the required modulus of the neck can be reduced by multiplying by a factor of 0.6. Rule: In order to be considered a short neck, the distance between the casting and the riser should be less than the minimum dimension of the riser neck.
Riser Neck
Step 11 How many risers are required for a casting? Rule: Only one riser should be used for each feed zone within a casting. Feed zones can be visualized by plotting the neck modulus, also called the Transfer Modulus. If more than one riser is used for a single feeding zone, in almost all cases only one of the risers will pipe and the other riser(s) will not pipe but will create a thermal hot spot underneath at which some shrinkage porosity will be likely to appear.
In every case, each casting has two risers and only one has piped.
Step 12 SOLIDCast uses the THERMAL MODULUS to calculate the location and extent of feeding zones within the casting. This is superior to the traditional measure of Volume:Surface Area Ratio, as it is able to take into account heat saturation of mold and core pockets as well as heat extraction by chills and, if desired, temperature distribution due to filling.
Step 13 The SOLIDCast Cast Iron Riser Design Program assumes that side risers are cylindrical with a hemispherical bottom, while top risers are cylindrical in shape. Rule: The tops of the risers should be above the highest point of the casting for gray and ductile iron casting, by at least the minimum section thickness.
Step 14 Gating should be designed to freeze relatively quickly after the liquid metal has filled the mold cavity. In general, this means that the gate attachment to the casting should have a 5:1 ratio of width to height to ensure relatively quick freezing so that expansion pressure can be contained. Remember, Control of Expansion Pressure is our ultimate goal in feeding cast iron.
t = A/5
t = A/3
As an example, consider the task of designing a feeding system for the following ductile iron casting.
This is the basic casting shape as imported from a CAD system in SOLIDCast.
Ductile Iron is selected as the Casting Material from the SOLIDCast database.
The casting is meshed with no risers or gates, so that a thermal simulation can be run for calculation of the Modulus of the casting.
Once the thermal simulation is complete, the SOLIDCast Riser Design Wizard is selected
and the user instructs the Wizard to calculate and display the Casting Modulus.
and from the Iso-Surface Plot Menu, we can read that the maximum Modulus of this casting is about 0.469 in. At this point, this is all the information we need from the Wizard, so we can just press Cancel to avoid making the plot at this time.
Another item of information well need is the weight of the casting. This can be easily obtained by selecting Mesh Weights from the main menu. Here we can see that the casting weighs 18.953 lb.
Now we are ready to calculate the properties of the iron, and the required riser size.
Here we enter the Carbon, Silicon and Phosphorus content of the iron.
And here we enter an estimate of the temperature of the metal in the mold.
Clicking the Calculate Iron Properties button causes the system to display the Shrinkage Time (ST) in terms of % Solid, and the net amount of Expansion (+) or Contraction (-) which occurs up to that Shrinkage Time. This is the quality of the iron without considering mold dilation.
Now that we have the properties of the iron calculated, we can design a riser for this casting.
First, we enter the casting weight as previously calculated by the system in the Mesh menu.
Next, we select the expected amount of mold dilation. This can be anywhere from less than 0.5% for a very rigid mold to more than 2% for a loose green sand mold. Here weve selected 1% for a well-made sand mold.
The next item to select is sleeve type. You can select either a sand riser (no sleeve), an insulating riser, exothermic or exothermic mini-riser. You can also select whether the casting is gated through the riser. The proportion of liquid metal removed from the riser is automatically adjusted.
Next we select the ratio of Height to Diameter that we want to use for the riser design.
Finally, we have the option to select either a Top or Side Riser. Here we have selected a Side Riser.
Now, pressing the Calculate button will display the required riser and neck size, as well as the Modulus of the neck and the riser. Note that the Neck Modulus is also referred to as the Transfer Modulus and can be used to indicate how many feeding zones (and now many required risers) there are for this casting.
Notice that by selecting the Short Neck option and repressing the Calculate button, we can calculate a neck size for a riser which is very close to the casting (closer than the minimum dimension of the neck).
Now by plotting the Transfer Modulus in an X-Ray View (Iso-Surface Plot) we can see that the entire casting is one feeding zone, so only one riser is required for this casting.
Another image of the Transfer Modulus, using CastPic plotting, also shows one zone which means one riser is required for this casting.
A more traditional Modulus calculation using Volume/Surface Area Ratio would have indicated two separate feeding areas, one in the central hub and one around the outer rim as shown here. Why is there a difference?
Heat Saturation
This cross-sectional view through the casting and mold shows temperature. You can see that the mold material becomes saturated with heat in the pocket areas between the inner hub and the outer rim, which keeps the thinner sections hot. This effect would not be captured by performing the old-fashioned Volume/Surface Area Modulus calculations, but is automatically taken into account when performing the Thermal Modulus function within SOLIDCast, because thermal effects in the mold are simulated.
Now that we have the riser and neck dimensioned, we also need to dimension the sprue, runner and gate, as well as estimate a fill time. The SOLIDCast Gating Wizard calculates an Optimal Fill Time of about 13 seconds for this casting (assuming a single casting).
And an inlet gate of about 0.23 in. x 1.13 in., which should ensure that the gate freezes quickly for control of expansion pressure.
Now we can use all of the calculated dimensions to create a simple system for gating and feeding this casting, which would appear as follows:
We use the results of the Cast Iron Calculation Utility Program to adjust the shrinkage curve parameters for the exact conditions of this iron chemistry, temperature and modulus value.
Shrinkage Time of 63%, amount of shrinkage = -1.1% minus Mold Dilation of 1% for a total shrinkage of -2.1%.
Using FLOWCast, we first perform a filling simulation of the casting, pouring metal down the sprue, through the gate and riser and into the casting cavity.
Finally, we use SOLIDCast to perform a simulation of the solidification of the casting and to predict the soundness of the final part.
Progressive Solidification
Shrinkage Prediction
The Final Result A sound casting, correctly designed using the SOLIDCast Riser and Gating Design tools, and verified using SOLIDCast and FLOWCast simulation.
www.finitesolutions.com
Ladle Calculations
Allows you to calculate capacities, flow rates and fill times from a given ladle. This utility also interfaces to FLOWCast and allows fill simulation using variable flow rates from a ladle.
Removes Material Density data from Riser Material areas so that you can see Material Density indications ONLY within the casting.
Allows you to plot fill times as calculated using the SOLIDCast (not FLOWCast) fill algorithm.
Project Viewer
Allows you to select any model, mesh or simulation in a project and display summary information about that item. For example, you can see exactly how a model was meshed for simulation, how many shapes are in a model, how long a SOLIDCast simulation took to run, and numerous other items of data.
QuickPlot
Lets you change the plot display quickly and easily. You can change the view, resolution and display method. You can also re-plot very quickly, to create a sort of animation.
This utility can be used to reduce the number of triangles, and thus the file size, of an STL file for easier loading and display in SOLIDCast.
This utility can be used to scale the size of a SOLIDCast model up or down (larger or smaller) by a given scale factor.
Simulation Parameters
This utility is used to set several simulation parameters that in previous versions of SOLIDCast had to be set by creating and editing text files in the installation folder. These files are still in use and can be adjusted by the user, but this utility simplifies their use.
This utility creates a display and a text file which gives System Information about your computer and your installation of SOLIDCast. This can be helpful to Finite Solutions in diagnosing problems or answering specific questions.
This utility calculates and places solidification time gradient calculations from a simulation into the Custom function so that they can be plotted. The Solidification Time Gradient has shown promise as a predictor of areas in a casting prone to hot tearing.
This utility is used to split large files into pieces so that they can be emailed (or placed onto media) and is also used to recombine the pieces. Many email systems still have limits on the size of attachments, which in some cases may be as small as 2MB. Video files created by SOLIDCast or FLOWCast will often be larger than this. The File Splitter Utility Program allows you to split these large files into pieces which can be emailed to another person and then recombined on the other end.
This utility allows you to create a single STL file of a SOLIDCast model, no matter how many shapes were used to build the model.
STL Slice
This utility is used to create a 2D slice at a given point through a binary STL file. The slice can be in the XY, XZ or YZ orthogonal planes. The output 2D data can be either DXF format, or in AFSCad format. This is often useful for establishing exact dimensions or locations of features on STL shapes.
This is a special-purpose utility which creates an STL file representing an intersection of two cylinders with a fillet radius around the intersection, like this:
This utility is used to set up a file that can be used by FLOWCast for a two stage pour process. For example, you could do the first 90% of filling from the sprue, pause for a number of seconds, then finish filling by pouring hot metal into the top of a riser.