AnyCasting Software Intro SAND Print

AnyCasting

TM

Advanced Casting Simulation Software

“ Any Service & Software will be Casting to Customers ”

Software Introduction (Sand Casting)

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

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AnyCasting

TM

Total Analysis of All Casting System ▶ 3-D Mold Filling Porosity, shrinkage/Solidification, Mold

Die

Sprue

Chill Vent

Pins

Pins

Slide Core

Cavity

Line Channels Core

Runner

Drag

Cavity

Shot Sleeve

Main Window of AnyCasting System (HPDC)

Main Window of AnyCasting System (SAND)

▶ 3-D Thermal Stress / Micro Structure / Mechanical Properties

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

2

Assembly Control of CAD Data Import & Assemble of 3D CAD/CAM Data ▶ UG, CATIA, I-DEAS, Pro/E, etc. ▶ CAD Operations (Merge/Boolean/etc.) ▶ Classify Parts : Product, Runner, Gates, Channels, O/F & A/V

AnyCasting CATIA

UniGraphics Import

PRO Engineering

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

Solidworks

User can use only STL format

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System Configuration Software Structure AnyCasting Standard AnyPRE AnySOLVER AnyPOST AnyMESH AnyDBASE BatchRunner

AnyCasting Performance    

HPDC/Thixo Module LPDC Module Permanent Mold (Tilt) Module Sand Module - Cast Iron - Cast Steel  Large Ingot Module  Investment Module

AnyCasting Extensible Module    

anyTX Advanced Material Properties Cast Iron Module Eject Pin Module

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

4

SW Configuration AnyCasting Work Flow ▶ Input Data & Solving & Observation

Input Data

Solving

- Modeling File (STL)

- Using Multi Core Process

- Meshing - Set Casting Condition

- Dramatic Decreased Solving Time

Observation Fluid - Entrapped Air / Gas - Oxide - Temperature - Velocity - Leakage

Solidification - Final Solidification Area - Micro / Macro Shrinkage

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

5

SW Configuration AnyCasting Work Flow ▶ Input Data & Solving & Observation

Input Data

- Modeling File (STL)

- Meshing - Set Casting Condition

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

-

Meshing Set TEMP. Set HTC Set Pouring Temp. Set Shot Condition Set Channel Set Cycle Condition

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SW Configuration AnyCasting Work Flow ▶ Input Data & Solving & Observation

Solving

- Using Multi Core Process

- Dramatic Decreased Solving Time

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

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SW Configuration AnyCasting Work Flow ▶ Input Data & Solving & Observation

Observation Fluid - Entrapped Air / Gas - Oxide - Temperature - Velocity - Leakage

Filling Sequence Melt Velocity

Temp. Distribution

Core Gas

Solidification - Final Solidification Area - Micro / Macro Shrinkage

Cast Iron Module - Tensile Strength

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

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Development Roadmap

2001

2008

V1.0

V5.0

V3.0

- Anycasting Release

-

-

Real Shape Large Ingot Centrifugal Casting Chinese Version

Predicting Oxide Shot Sleeve Setting Vacuum Setting Melt Supply Setting Thermal Stress Analysis

-

V4.0

2005

2010

V6.1

- Multi Process - Cast Iron - Predicting Eject-Pin Stability

Real Flow Filter Auto Report Calculating Properties Multi Language Predicting Core Gas

V2.0

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

2014

2012

-

-

Enhanced Particle Tracing Enhanced Channel HTC Exothermic Sleeve CPU Core Setting

Auto Mesh Enhanced Centrifugal Casting Quantitative Analysis Result Combination Predicting Gas Defect

V6.0

2013 9

Exact View by Dynamic Arbitrary Section Observe Inside of All Entity Parts ▶ X, Y, Z 3 Direction Dynamic Moving Section View ▶ Detail Observation of STL Geometry & Calculation Result

AnyPRE Process

AnyPOST Process

Rotating (Free Section)

AnyPOST Process

Moving

▶ Dynamic Arbitrary Section Function be Provided Continent Observation to User ▶ User can Check Inside of All Entity Parts Easily Where is Thin or Thick Area

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

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Graphic Speed Acceleration Fast Graphics & User Interface ▶ Fully 3D (Open GL 3D), Fast Algorithm: Surface Compiling Method ▶ Set All Conditions by Graphics User Interface

Dynamic Section Viewing

Set Material by Mouse Clicking

Number of Mesh : 31 Mill. Automatic Gate Detecting, Set Gate Condition

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

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Fast Meshing Algorithm Meshing Speed : 5 sec per 20 Mill. Mesh ▶ Surface Vector Tracking Method ▶ Intersected Polygon’s Normal Vector Analysis

STL Geometry

Meshed State

Analysis of Geometry & Mesh by 3-D Graphics in Pre-Processor

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

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Auto Meshing 3-clicks is enough for mesh generation! ▶ Find the best meshing condition automatically ▶ Check thin sectioned area automatically ▶ AnyCasting S/W has Uniform / Variable / Auto Mesh System

Generation of 21 Mil. Mesh : 3.5 sec

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

Check important sectioned area by using Cross Section

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Parallel process Up to 2-times Analysis Speed Improvement ▶ Test PC Performance - Intel i7-4770 3.4GHz / RAM 16GB ▶ Analysis Type - Filling & Solidification

(1 CPU)

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

(8 CPU)

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Advanced Material Database User can Make Specific Material Database ▶ Just Input Chemical Composition of Material ▶ Material Database be calculated in a few second and apply to anyPRE

Input Chemical Composition

Calculate Thermal Properties

Input Calculated Thermal Properties

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

15

Trace of Curved Boundary of Mold Interface Trace Mold Interface by Sub-divided Mesh (Scheme of Cut-Cell Method) Trace Curved Boundary of Mold Interface Make Sub-divided Mesh (Meshing Condition Control) Trace Interface Surface in Boundary Cell using Sub-divided Mesh

Boundary Cell for Trace Interface Surface Fluid Cell for Pressure Interpolation

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

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Plexiglass-water Model Experiments Filling Accuracy Comparison with Plexiglass-water Model : ▶ Gravity Casting

General FDM Solver

Hybrid Scheme

Experiment

(Real Flow)

(movie file)

(movie file)

Fluid Fills Runner Partially (Experiment & Real Flow) Filling Flow goes Faster along the bottom of Runner (same)

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

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Filling Accuracy at Wall of Sand Mold - 1 Filling Accuracy in the Casting of Cat Iron Product ▶ Ductile Cast Iron / Sand Casting

Gate 4, Filling Flow is Main Stream, It Fills near Gate 4 Fast, Move Forward during Filling Process

G2

G4

G1

G2

G3

G4

Filter

Core

Gate 4, Filling Flow is Weak, It doesn’t Contribute to Initial & Whole Filling Process.

G3

Runner

Runner

General FDM Solver

G1

Hybrid Method

Cavity

Riser

(Real Flow)

Core

Bracket, Weight : 42 Kg FCD 600, Green Sand / Shell Core

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

18

Filling Accuracy at Wall of Sand Mold - 2 Temperature Distribution during & after Filling ▶ Ductile Cast Iron / Sand Casting

General FDM Solver

Hybrid Scheme (Real Flow) 50% Filled Temp. Distribution

Changes : Metal Structure, Sol/ Shrinkage, Miss-Run, Sand Drops, Crack Area, etc.

Gate 4, Filling Flow is Weak, Gate 4, Temp. is Lower, Lowest Temp. shows at Center Area.

Gate 4, Filling Flow is Strong, Gate 4, Temp. is Higher, Lowest Temp. shows at Right Area.

100% Filled Temp. Distribution

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

19

Tracing of Retained Melts - 1 RMM (Retained Melt Modulus) or RMS (Retained Melt Surface) ▶ Tracing of Retained Melts, and Calculate Modulus or Surface Area mainly for Macro Shrinkages

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

20

Tracing of Retained Melts - 2 RMM or RMS ▶ Calculate Volume/Surface and Modulus mainly for Macro Shrinkages

Tracing of Retained Melts’ Volume and Surface Coupling RMM or RMS with Probabilistic Model

RMM : Retained Melt Modulus

M R.M . 

VR.M . S R.M .

Shrinkage Size change Distribution of total Shrinking Volume

PM : Probabilistic Model

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

21

Theory & Dev. of Probabilistic Model Shrinkage Probabilistic Model : ▶ Predict Macro & Micro Shrinkage Size & Range Shrinkage Probability (Psh)

1

Calculated Shrinkage Intensity be Analyzed by Probabilistic Distribution

β’ 0 0

ω’

1

Cumulated Frequency (ω)

Shrinkage Probability :  '    '   (1   ) cos '     2  PSh   '     ' 1  sin       '  2(1   )      

for    ' for    '

Total Shrinkage Volume by Alloys & Volume change by Casting Conditions Determine Size Range

Shrinkage Conservation : 1

P 0

Sh

d  '

β’ : Shrinkage Potential

(Ref. Sung-Bin KIM, etc., Korea Foundry Society’s Conference, 2001)

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

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Coupling RMM & G/ V with Probabilistic Model Comparison of Coupled Analysis ▶ RMM & G/V with Probabilistic Model RMM (Retained Melt Modulus)

Coupled RMM + PM Analysis

Tracing of Isolated Retained Melts Mostly Predict Macro Shrinkages, Sometimes Micro Shrinkage, as well.

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

G/V Model, Niyama

Coupled G/V(Niyama) + PM Analysis

Micro Shrinkages were Calculated by Insufficient Liquid Feeding into Dendrites, It Shows Shrinkages of Various Size at Broad Area of Casting. 23

Feature of Sand Casting (Cast Iron / Cast Steel)

Contents 1.

Filter

2.

Mold Erosion / Sand Drop

3.

Core Gas

4.

Exothermic Sleeve

5.

Exothermic Powder

6.

Cast Iron

7.

Shrinkage (Critical Solid Fraction)

8.

Shrinkage Volume

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

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Accuracy Flow include Filter for Stable Filling ▶ Exact Filter Analysis & Consider all Directions

4 Direction Flow under installed Filter Condition Sprue Filter Runner

No Filter Case

Filter Case

Filter Case (Pressure)

keep stable pressure

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

Filter Case (Velocity)

keep stable velocity

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Mold Erosion & Sand Drop Model ▶ kind of Mold Material & Melt Temperature are very Important

Er  K mat K env CV n f ( ) Er  Erosion rate (mg / s ) K mat  Material constant K env  Environmen tal constant C  Concentration of particles f ( )  Function of impact angle  V  Impact velocity

The Relationship between Erosion Rate and Impact Angle ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

The Relationship between Erosion Rate and Velocity 26

Sand Drop Test by using Cylinder Block ▶ Compare Horizontal Design and Vertical Design

Horizontal Casting Design

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

Vertical Casting Design

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Observe Melt Velocity During Filling for Judge Sand Drop ▶ Melt Velocity Distribution between Water Jacket and Core : Cylinder Block

Horizontal Runner Design

The rapid velocity of melt can be a cause of sand drop defect

Vertical Runner Design

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

28

Core Gas Model ▶ Mathematical Formulation of Core Gas -

Movement of Gas in Porous Core : Darcy’s Flow Core Gas Pressure : Ideal Gas Raw Mass Transport Equation Solid Binder Decomposition Rate : Arrhenius Relationship by Pyrolysis Study Movement of Gas in Melt : Basset-Boussinesq-Oseen (BBO) equation

Out Gas from Core (g)

Gas in Cavity (g/cm3)

Cold Box Sand Core

Core Print

Cast Iron

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

29

Tracking Core Gas during Filling ▶ kind of Mold Material & Melt Temperature are very Important

Horizontal Runner Design

Horizontal design has higher possibility of Core Gas defect than Vertical design

Vertical Runner Design

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

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Exothermic Sleeve Model ▶ Exothermic Sleeve by Numerical Analysis -

Insulating Sleeve : Sleeve for just adiabatic effect Exothermic Sleeve : Automatically generate a heat when contact melt

Main Factors for Calculating Exothermic Sleeve • Sleeve Type • Burning Time • Ignition Temperature • Heat Rate





  ( cT )    VT    kT   b (t ) t

b : Heat Generation Rate [cal / s  cm 3 ]  0 ( TIgnition ) b    f (t ) ( TIg int ion )

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

31

Exothermic Sleeve Model ▶ Simple Model Test : No Sleeve / Sleeve (Low & High Effect) -

Insulating Sleeve : Sleeve for just adiabatic effect Exothermic Sleeve : Automatically generate a heat when contact melt

No Sleeve

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

Low Effect Sleeve

High Effect Sleeve

22mm

42mm

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Exothermic Powder Model ▶ Exothermic Powder by Numerical Analysis -

Raise the Feedability of Riser for reduce the shrinkage defect Generally, be used Large Ingot & Huge Cast Steel Product

Spread Exothermic Powder

Control Solidification Direction

Main Factors for Calculating Exothermic Powder • Exothermal Area after Filling • Surface Heat Flux by Time • Surface Heat Temperature by Time





   ( cT )    VT    kT   s (t ) t xs

s : Surface Heat Flux [cal / s  cm 2 ] xs : Surfacedistance [cm]

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

33

Exothermic Powder Model ▶ Exothermic Powder by Numerical Analysis -

Raise the Feedability of Riser for reduce the shrinkage defect Generally, be used Large Ingot & Huge Cast Steel Product

Use Only Exothermic Sleeve

Use Exothermic Sleeve & Powder

Shrinkage Defect Shrinkage Defect

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

34

Cast Iron Module ▶ Predict Phase Distribution & Mechanical Properties -

Consider Effect of Chemical Composition (Si, Mn etc..,) Consider Fading Effect of Inoculation

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

35

Cast Iron Module ▶ Predict Phase Distribution & Mechanical Properties -

Consider Effect of Chemical Composition (Si, Mn etc..,) Consider Fading Effect of Inoculation

Gray Cast Iron : A48 Phase Distribution of Pearlite

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

Gray Cast Iron : A48 Mechanical Property of T〮S

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Selection of CSF (Critical Solidification Fraction) ▶ Selection of CSF at Mushy Zone for Output of Solidification Info. CSF : Critical Solidification Fraction 0.1~0.3 0.5 0.7

(Ref. D.M. Stefanescu, etc. 1985, Y.X. Li, B.C. Liu, C.R. Loper Jr., 1990)

Output of Core Sol. Info. : - Retained Melt Surface - Retained Melt Volume - Temperature Gradient - Cooling Rate - Solidification Time - Local Solidification Time - Interface Moving Velocity etc.

Shrinkage Prediction Model (Ref. D.M. Stefanescu, L. Dinescu, 1979)

Shrk Size, Position, etc. Change

(Ref. Dongmei Liu, Xinzhong Li, etc.) ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

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Mismatch between Actual Shrinkage & Analysis ▶ Mismatch between Actual Shrinkage and Simulation Prediction Defect 2

No Shrinkage Defects in Simulation Shrinkages are Too Close to Core

Defect 1

Actual Shrinkages in Factory

No Shrinkages in Actual Castings

Simulation Prediction ( RMM + PM )

▶ Current Shrinkage Model and CSF in Simulation 1. 2. 3.

Material : GCD600 (KS Standards) Shrinkage Model : RMM (Retained Melt Modulus) Total Feeding Ratio =0.7(70%), CSF (Critical Solidification Fraction) =0.5(50%) ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

38

Comparison of Shrinkage Model & CSF - 1 ▶ Comparison of RMM & RMS with Variation of CSF CSF=0.1

CSF=0.2

CSF=0.3

CSF=0.4

Retained Melt Modulus Retained Melt Surface ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

39

Comparison of Shrinkage Model & CSF - 2 ▶ Comparison of RMM & RMS with Variation of CSF CSF=0.5

CSF=0.7

CSF=0.9

Retained Melt Modulus Retained Melt Surface ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

40

Comparison of Shrinkage Model & CSF - 3 ▶ Comparison of RMM & RMS (CSF=0.1, Feeding Ratio=0.9) Actual Shrinkage Pattern & Positions A

A’

B

B’

C

C’

D

D’

Coupled RMM + PM

Coupled RMS + PM

Section Position for Shrinkage Defects Observation

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

41

Comparison of Shrinkage Model & CSF - 4 ▶ Comparison of RMM & RMS (CSF=0.1, Feeding Ratio=0.9) Actual Shrinkage Pattern & Positions A

A’

B

B’

C

C’

D

D’

Coupled RMM + PM

Coupled RMS + PM

Section Position for Shrinkage Defects Observation

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

42

Shrinkage Volume Model ▶ Basic Assumption -

Shrinkage Rate of Liquid Pocket be proportional to it’s volume Total Shrinkage Volume is Same as Total Liquid Pocket Volume

▶ Basic Equation -

Shrinkage Volume of Isolated Liquid Pocket

Vi shr 

V

shr n

Vi  V0    f s Vn

V1

V2

 V0    f s  V0shr

V0 : Total Volume Vi : Volume of i  pocket Vi shr : Shrinkage Volume of i  pocket

 : Volume Shrinkage ratio f s : Solid fraction ⓒ 2001 ANYCASTING Co., Ltd., All Rights Reserved

43

Shrinkage Volume Model ▶ Consider History of Solidification & Liquid Pocket Size

▶ Express an Absolute Unit (cc) for Shrinkage Volume

Cast Steel : CG 8M Solidification Pattern

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

Shrinkage Volume

44

AnyCasting Co., Ltd

Thank You !

AnyCasting Co., Ltd. www.anycasting.com

Headquarter

Gimhae Plant

B-16F Woolim B/D, 583 Yangchun-ro, Gangeso-gu, Seoul, Korea TEL 82-2-3665-2493 FAX 82-2-3665-2497

123-18 Gasan-ro, Hallim-myun, Gimhae-si, Gyeongnam, Korea TEL 82-55-345-2016 FAX 82-55-345-2017

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

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