cast-designer... using hdi for riser design 20 read in the part geometry in 3d cad data or stl data....
TRANSCRIPT
Cast-Designer
-- Full Engineering Solution for Casting Industrials
www.auto-design-online.com
C3P Software: Digital Manufacturing Solution Provider
2
• Focus on virtual manufacture process to help industry to catch up ‘Time to Market’ and ‘Quality to Market’
– Full solution for metal casting and assembly
– Sheet metal forming design and simulation
– Integrate expert system and CAE technology
– Very close research relationshipwith top level research institute and universities.
– Innovation technology compared with tradition design and CAE method, build in upfront analysis.
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Cast-Designer International Network
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C3P Software offices Value add international resellers
• Formally US base company, very care of the development of new business region
– Shift software R&D to Asian step by step since year 2006
– More than 50 industrial projects each year
– Strong support and distributor channel
– Faster development, one major release each year.
Asia Pacific: Australia, China, India, Japan,
Korea, Malaysia, Singapore,Taiwan, Thailand, Vietnam
Europe: Italy, Germany, Hungary, Poland,
Spain, Turkey, Russian
North America: USA, Canada, Mexico
Latin America: Brazil Africa: South Africa, Egypt Over 70 dedicated team members in
the world supporting our products
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Product, Partnership, Customer
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Cast-Designer
Form-Advisor
Geo-Designer
www.core-capital.com
www.ascentvp.com
www.rockfordcapital.com
Our products Solid financial status Partnership and selected customers
The sole solution provider for casting business from part to production.
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Product, Partnership, Customer
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Cast-Designer
Form-Advisor
Geo-Designer
www.core-capital.com
www.ascentvp.com
www.rockfordcapital.com
Our products Solid financial status C3P University
The sole solution provider for casting business from part to production.
To help young people familiar new technology and casting business.
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Cast-Designer Solution
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3D PartDFM Check
QuotationPrepare
GatingSystem
ManufactureProduction
CAE Analysis(FEM + CFD7.2)
AutomaticOptimization
Cast-Designer
SavingCAST(Material)
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Casting Process and C3P Software Solution
Example in sand casting
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Casting Process and C3P Software Solution
SavingCASTC3P Software
Example in sand casting
Cast-DesignerC3P Software
Cast-DesignerC3P Software
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What is SavingCAST?
SavingCAST is a software specially developed for foundries, designed for optimal selection of loads for any type of league. Automatic calculation of casting with cost optimization using the relevant information of the raw material in stock, always within the constraints imposed by the user.
In today’s business environment, the spread sheets are no longer enough. With SavingCAST, it is possible to make your castings at the lowest cost and manage all the production system together.
SavingCAST can save time and money to be competitive in the new global market.
SavingCAST will let you prepare your charges at the lowest cost, saving time, avoiding human error, managing the stock and keeping track of your operations.
SavingCAST also suitable for all casting process.
Reducing costs.
Improving quality.
Optimizing resources.
Contributing to sustainable development.
Achieving operational excellence.
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Amount %
1 Iron (Raw) 1,099,971.6 47.58%
2 Scrap Steel 8,955.0 0.39%
3 Salary 562,037.0 24.31%
4 Electric power 64,560.0 2.79%
5 Smoke power 27,444.0 1.19%
6 Bontonite 35,588.0 1.54%
7 steel ball 20,480.0 0.89%
8 mold sand 6,730.0 0.29%
9 Coke 147,963.0 6.40%
11 Silicon sand 2,752.0 0.12%
12 Hardware materials 110,547.0 4.78%
13 Welfare fee 622.0 0.03%
14 repair costs 978.0 0.04%
15 Food expensens 31,330.0 1.36%
16 Rent cost 9,200.0 0.40%
17 transport fee 11,405.0 0.49%
20 Medical insurance 357.0 0.02%
21 others 3,475.0 0.15%
subtotal of production 2,144,394.6 92.75%
23 Sell -Transport fee 49,024.0 2.12%
24 Mgr - Travel costs 25,665.0 1.11%
25 MGr - Office expenses 777.0 0.03%
26 MGr- Insurance 120.0 0.01%
27 MGr - Drink water 1,745.0 0.08%
28 MGr- Hospitality fee 4,907.0 0.21%
29 MGR - Consultation fee 3,600.0 0.16%
30 FA- Interest expense 76,200.0 3.30%
32 FA- Discount fee 5,545.0 0.24%
Subtotal expenses 167,583.0 7.25%
Total costs 2,311,977.6 100.00%
April (in RMB)
DescriptionS/NCost Structure Example
47.97%
9.48%3.62%
24.31%
14.62%
0.00%
10.00%
20.00%
30.00%
40.00%
50.00%
60.00%
Rawmaterial
Poweretc.
Suppliermaterial
Salary Otheroperation
Cost structure
Cost structure example of a sand casting company, the raw material is the main cost and achieve around half of the total cost.
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Charging Example – Steel: Result Comparison
Plan1: Experience charging
Result: 17.44 CNY/Kg
NG NG NG
NG
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Charging Example – Steel: Result Comparison
Plan2: Other System
Result: 15.90 CNY/Kg
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Charging Example – Steel: Result Comparison
Plan3: SavingCAST
Result: 13.39 CNY/Kg
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Charging Example – Steel: Result Comparison
17.44
15.9
13.39
5
7
9
11
13
15
17
19
Experiencemethod
Other system SavingCAST
Cost per Kg
Cost per Kg
Total cost: 348,800
Total cost: 318,000
Total cost: 267,800
Save30,8008.8%
Save81,00023.2%
Reference
For a furnace in 20ton to calculate the total cost
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SavingCAST: Advantages of the Program
Very easy to use. One hour training course only!
Efficiency and speed of calculation within the process of production and under constantly changing assortment of charge materials and alloying additives;
Getting the set chemical composition at minimum cost of charge materials;
Sending the received results to the calculation database for their further printing (transfer, processing, etc.);
Multi-language interface of the software;
Flexible business plan for the software license;
The pay back period for SavingCAST has never exceeded one month.
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Full Chain of Casting Industrials
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3D Part
DFM Check
Quotation
Prepare
Gating
System CAE Analysis
Manufacture
Production
1 2 3 4 5
3D Product
Gating System Design
Process Analysis
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What is Geo-Designer? (I)
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• Geo-Designer is a powerful upfront Design for Manufacturing (DFM) tools for designers and manufacturing engineers with innovative technology.
• It accelerates the design process for functions, manufacturability, enabling designs to move to production better and faster.
• Geo-Designer is powerful, flexible, fast and easy to use and provides savings in downstream costs by quality improvement at the design stage.
• Geo-Designer offer a new method to study the part geometry in 3D Iso-surface with flexible transparently, it is similar the x-ray and CT method in industrial.
• Geo-Designer can analysis the product thickness, draft angle or undercut and fillet radius. Ray method and the Mass Distribution Index (MDI) are supported for geometry analysis.
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What is Geo-Designer? (II)
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• Geo-Designer can analysis the heat transfer and distribution for the casting process. The Heat Distribution Index (HDI) analysis is much faster and simple than any numerical simulation method.
• Geo-Designer can make slider analysis to support mould design.
• Geo-Designer can make ejection force analysis for both value and distribution to support ejection pin design.
• Geo-Designer can make core checking and design for gravity casting part.
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Geo-Designer Could Be Used for …
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Mass distribution
Wall thickness
Draft Checking
Fillet Radius
Core checking
Cooling rate
Riser & Gate
Heat distribution
Slider Checking Ejection Force
Chill Design
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Using HDI for riser design
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Read in the part geometry in 3D CAD data or STL data.
Read in the riser, chill and gating system one by one.
Assign different material properties to riser, gating, chill and insulator.
Generate the Geo-Designer model and make HDI analysis.
The last picture show the result of HDI =15. the affection of the chill to heat distribution is clear (the red arrow).
1 Min.
• Design the location of riser
• Check the size of riser
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Using HDI for riser design
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We continue check the HDI in higher value, such as 20, 25, 30 and 35.
The region with arrow is high risk for shrinkage porosity after the casting process. So the user can adjust the size and locations of the risers to achieve a better result.
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Application: Geo-Designer for Engine Block
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Geo-Designer could be used to check the basic information of the part, to guide the product design and provide more detail information for manufacturing process design. The information includes,General thickness of the partSection thickness of the partPart information such as volume, mass, surface area, geometry modules, projection area in X/Y/Z direction
Part Checking:
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Geo-Designer for Engine Block: casting checking
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Geo-Designer provides function for slider checking. The red color region must use slider to help eject the part after casting. This information is very useful for die designer.
Slide checking: Core checking:
Sand core checking is very important for the complex part, such as engine block. It should be useful to check the weak sections of the core at product design stage.
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Geo-Designer for Engine Block: Riser design
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Geo-Designer provides a quick analysis of the thicker wall zone and such information could be used for riser & feeder design.
Region volume and mass in higher HDI could be used for riser size design after consider the riser effectively.
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Geo-Designer for Engine Block: Riser design
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Build in riser design functions to provide online riser design capability and check it immediately.
Support box, cylinder, cone and ball design. Support STL import for addition fuse and substrate for more complex geometry.
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Geo-Designer for Engine Block: Riser design
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Take the online design object as CAD import and make some fine turning.
Final design after consider the real geometry of engine and casting process.
MDI check
Location?
and
Size?
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Ejection force calculation, slider analysis
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Applicants
Part base analysis in
an express way
3 to 5 min to get the
first result.Slider zone checking to help
mould design
• Ejection force
analysis, locking
force analysis
• Setup the mold
side, and distribute
the ejection pin
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Geo-Designer for Part Optimization
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Example part: Load to Geo-Designer. MDI analysis.
Add control points to move the critical region.
More points could be added in one model.
Part optimization: material be removed.
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Geo-Designer for Part Optimization
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Part optimization: material be removed.
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Full Chain of Casting Industrials
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3D Part
DFM Check
Quotation
Prepare
Gating
System CAE Analysis
Manufacture
Production
1 2 3 4 5
3D Product
Gating System Design
Process Analysis
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Casting Costs & Quotation
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Yearly volumeBatch volumeLead timeYield ratio
Production rateAlloy / MaterialMachine & equip.ManpowerSub-contractother costs
Mould costWorkshop TransportStorageFinancial costManagement costSelling cost
Total costSelling price
ProfitsRevenue
Manufacturing costs
Operation costs
Customer order
Quotation
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Casting Costs & Quotation
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A quotation tools in Cast-Designer for cost calculation. It could be used for cost evaluation after the DFM analysis for all casting process.
This quotation calculator was evaluated by many customers in different casting field.
The user can customize the currency, alloy, machine and manpower cost, then calculate the casting cost based on the production rate, volume, manufacture cost, and other cost.
Finally a multi-language quotation sheet could be generated in Excel file format.
Project Information
Product: Part Name:
Part Number: Enquiry No:
Customer: PO No:
Prepared By: Date:
Comments:
Mass of casting: 3 Kg Casting machine:
Mass of gating system: 1.5 Kg cost per hour: 9.8 /hr
Cycle time: 65 Sec Cost of operator: 12 /hr
Number of Cavities: 1 Casting Alloy:
Production rate: 55.4 pcs/hr
Annual quality of part 400,000 pcs Currency Used:
Production batch size 40,000 pcs
Machine cost 0.187 /pcs Good movement cost 0.007 /pcs
Labour cost 0.206 /pcs Good despatch cost 0.004 /pcs
Material cost 4.05 /pcs Storage cost 0.003 /pcs
Scrap cost: 0.04 /pcs Freight cost 0.57 /pcs
others 0.083 F&A cost 0.1 /pcs
subtotal 4.566 Subtotal 0.684 /pcs
Selling cost 0.184 /pcs Annual sales value
Selling price 6 /pcs Annual total costs:
Profit margin 9.43% /pcs Annual profit:
machine cost 0.187
Labour cost 0.206
Material cost 4.05
Scrap cost 0.04
other cost 0.951
profit 0.566
Demo
C3P Engieering Software Cost sheet
cover
1234-12C1
ABCD
Ben
cover-1
4567
567
2014/8/18
Casting data and production rate
ADC12
Ton350
Machine and casting alloy:
USD
2,173,600.00
226,400.00
Cost structure overview
Cost of manufacturing process Cost of movement and storage
Selling cost and sales price Revenue and profit
2,400,000.00
machine cost
Labour cost
Material cost
Scrap cost
other cost
profit
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Full Chain of Casting Industrials
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3D Part
DFM Check
Quotation
Prepare
Gating
System CAE Analysis
Manufacture
Production
1 2 3 4 5
3D Product
Gating System Design
Process Analysis
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Gating System Design Interface
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Casting system design
Now, all the casting system design functions
have been summarized to one unique window
interface. The unique interface services to all
casting process like HPDC, LPDC, gravity
and investment casting process, also all
casting components like the gating system,
overflow system, cooling and venting system.
More ever, the shot sleeve design is also
redesigned and included in the gating system
design wizard, the vacuum valve setting also
could be analyzed during the shot sleeve
design.
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Turn your design concept to 3D data in a quick way
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1
2
It is really hard for me to make a clear decision before I have a detail 3D casting system…
No problem! Cast-Designer can do that in a few minutes …
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Cast-Designer for Casting System Design
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Cast-Designer BASIC is an efficient 3D CAD tools with expert system special for HPDC
Expert
Power
Platform
An Expert System for Gravity Casting System design to help designer and engineer make a reasonable casting system in a quick way
Designer application Includes riser, feeder, gating system , chill, well and cooling system
Standard alone software based on last Open CASCADE technology or fully integrated to common MCAD system, such as Pro-E, UG NX, SolidWorks etc
Usage
Data
Learning
The design approach is much faster and simple compared with tradition CAD system and fully parametric
Standard and special data exchanger for 3D CAD system and CAE system
Short learning curve and enhance company design ability shortly
Cast-Designer BASIC is an efficient 3D CAD tools with expert system for Gravity Casting
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Cast-Designer: Riser & Feeder design
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Riser & Feeder Design
Build in wizards or calculators to guide the user swiftly towards the optimized design of a feeding and gating system
Riser Design Rule:
• Time condition: Solidification
• Volume condition: predict the delivered volume of open or blind riser or isothermal sleeve
• Distance condition: feeding
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Casting Design Advisor
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Gating System Design Advisor
metal, mass, quality requirement
Casting Volume
Riser & Feeder
Filling Time
Inner Gate
Help solve the solidification problems
Casting alloy, Casting part geometry
Nbs, section area
(Design finished)
Fine turning
Sprue runner
Runner
Speed Up Ratio
Nbs & section area, shape parameters
Design runner, Nbs & section area
Increase ratio of pouring system/Spure: Runner :
inner gate
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Template design for Gravity
39
Re-write the one button design engine with new template format.Re-organize the template.
New interface for parameters editing.Much better CAD quality than before, support fillet radius between segments.Support runner in arc curve.
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‘Template design’ for Gravity casting
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Template design for gravity casting gating system
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Template gating system design procedure Full parametric design, very easy to adjust the shape and dimension.
• Main parameters to control the major dimension and shape minor parameter to control the details.
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Cast-Designer: Runner design
42
Gate & Runner Design
Build in wizards or online help to guide the user swiftly towards the optimized design
• Full casting system design (inner gate, runner, Sprue runner, chill, well, cooling system …)
• Very similar interface for all design components
• Multi-objects support, Multi-plan support
• Full 3D model, support draft design concept
• What You See, What You Get work style (WYSWYG)
• Flexible coordinate adjustment, flexible objects operation
• Data template concept, import and export data template.
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Cast-Designer: Sprue Runner design
43
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Enhance Free Design Functions
44
Enhance free design functions to control the section of runner.
Redesign the toolbar and function buttons.
Control everything in the mouse operation.
Much powerful in 3D runner design.
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Free Design Functions
45
• More flexible to control section dimension and
details in mouse and immediately panel.
• Section angle free adjustment (New)
• Smooth curve for connection.
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Section Control & 3D Gate Generation
46
More friendly interface for section control and adjustment.
Mouse control the ‘Z’ coordinator for 3D gating system, very simple and easy to use. Now everybody can generate 3D runners.
More parameters in sections for special gating system.
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Gating Revise in Free Design
47
1 2 3
3
44
• Reverse Engineering for existed gating system from
ANY CAD system (CAD, STL, mesh etc.)
• Convert to full parametric gating in a few minutes
1. Original gating CAD
2. Fast meshing to split to different
runners
3. Draft runner on existed CAD surface
4. Revise to Cast-Designer digit runner
in fully parametric.
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Gating Projection in Free Design
48
1
2
34
Design the gating system in a plane and control the section area /dimension. Also display the core/slider in the main view.
Adjust the section numbers in the projection region. Adjust the section angle (if any)
Project the runner to the slider/core/3D surface.
Obtain the 3D runner with accurate dimension.
• Final result of
gating projection
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‘Free Design’ & Complex Gating System
49
3D feature line
3D gating system
In Cast-Designer, the start point has beenshifted to casting part stage sine the systemgenerate gating system directly.
Gating system and simulation of automatic part
Gating system of engine block Gating system of permanent mould gravity casting
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Cooling system design
50
New interface for cooling system design.
Support cooling group, channel and segments.
Online wizard for all cooling channel length
Powerful online analysis (unique)
Cooling channel
Heat balance guide
Fast cooling model
Cooling affection analysis
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Cooling Channel Analyze: Cooling Affection
51
Combine both the EMDI and fast cooling result together to cooling affection result. The negative value region should take care of.
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Win business on the start point
52
Design
Time from ‘Design’
Quality from ‘Design’
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Full Chain of Casting Industrials
53
3D Part
DFM Check
Quotation
Prepare
Gating
System CAE Analysis
Manufacture
Production
1 2 3 4 5
3D Product
Gating System Design
Process Analysis
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Powerful 3D Mesh Generation
54
CAD
MESH
CAD
MESH
CAD
MESH
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Cast-Designer Dual Solver
55
FEM CFD
PK?
Dual Solver Technology
Cast-Designer v7
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Design 2
Cast-Designer CPI to check the flow result
56
Design 1
Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.
• The Flow results includes the temperature, flow pattern, velocity, fluid factor, gas entrapment etc.
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Design 2
Cast-Designer CPI to check the solidification result
57
Design 1
Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.
• The solidification result includes the solid factor, temperature, hot spots, shrinkage porosity etc.
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Shrinkage porosity and micro-porosity
58
Cast-Designer CPIResult shows the Shrinkage porosity the yellow one, it was due to the last solidification. And the micro-
porosity, it due to the cooling rate of the solidification process, the red one.
Design 2Design 1
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Design 2
Design 1
Mechanical stress and deformation
59
Average Normal Stress
Average Normal Stress
Effective Stress
Effective Stress
Part deformation after casting
Part deformation after casting
Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.
• The basic result of stress includes the stress & strain, part deformation, hot cracking and life time.
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Design 2
Design 1
Micro-structure analysis the solidification & cooling
60
Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.
• The micro-structure results includes the temperature, phase transfer, mechanical properties etc.
SDAS % of Pearlite
SDAS % of Pearlite
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Design 2
Design 1
Mechanical properties of the casting part
61
Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.
• The micro-structure results includes the temperature, phase transfer, mechanical properties etc.
Tensile stress Yield stress
Tensile stress Yield stress
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Design 2
Design 1
Mechanical properties (hardness)
62
Cast-Designer CPIPerform a quick simulation, include the thermal, flow, stress and microstructure result.
• The micro-structure results includes the temperature, phase transfer, mechanical properties etc.
Hardness (HRB)
Hardness (HRB) Hardness (HRB)
Actual test HRB217.04
226.8
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Cast-Designer CPI Flow Chart
63
CAD DataGate System
CPI Meshing
CPI Setup
Cast-Designer CPI
Post Result
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Machining Part: defects analysis (Shrinkage porosity)
64
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Complex gating system for gravity Casting
65
Casting system design35 min
Meshing with all components and CPI setup 20 min
Mixed meshing for casting part and cores, 323,100 elements for casting
Metal flow was not balance for the three parts Temperature drop too much (right)
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Meshing technology in Cast-Designer CPI
66
• Innovation technology for meshing generation
• Very simple for operation
• With coarse mesh, mesh layer and advance geometry mapping (mesh smoothing) technology
• Extremely better for accurate in filling pattern and pouring time
CAD model
Mesh model Enlarge the CAD & Mesh
This model includes 118,544 elements, and take 2 minutes for mesh generation.
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Examples of Cast-Designer CPI
67
Cast-Designer BASIC is an efficient 3D CAD tools with expert system special for HPDC
Sand Casting
permanent gravity casting
DISA
Tilt Casting LPDC
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Mould assembly for permanent gravity casting
68
CAD Model
Powerful mould assembly function in Cast-Designer
The Cast-Designer technology can not only provide a quick meshing and mesh
assembly, but using the mixed meshing technology to reduce the model size
to minimum. For example, for the above model, the meshing time was only
28 min and full automatic. The affection ratio of the node of casting can
achieve to 47.8%, it is really very high for this kind of applicant.Mesh model
Top Die
Bottom Die
Sand Core
Casting Part
721,320 elements
195,099 nodes
Tetrahedron
436,679 elements
604.052 nodes
Hexahedron
776,328 elements
203,632 nodes
Tetrahedron
976,940 elements
259,331nodes
Tetrahedron
Advance
module
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Mould assembly for permanent gravity casting
69
Advance
module
Mixed elements for casting & mould
Powerful mould assembly function in Cast-DesignerThe powerful mesh assembly function of Cast-Designer can reduce the meshing time to 10 to 30 min for any complex model, it is full automatic.
Complex mould with more than 15 components
25 min for mould assembly & meshing
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Advance CFD flow solver and applications
70
Advance
module
Simulation result of Cast-Designer CFD Solver vs experiment.The experiment was performed by Dr. Markus Schmid at ARGE Metallguss in Aalen, Germany
(a) X-Ray photo of the actual part
(b) Gas entrapment of simulation result
(c) Flow pattern shows gas entrapment
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Mechanical stress and deformation analysis
71
0.6mm outside
2) The dimension of the heat sink was changed after the casting process.
1) The side wall with 0.6mm deformation, match the actual part.
Advance
module
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Stress and deformation analysis
72
Mechanical Stress Module:
Cast-Designer with mechanical stress and deformation simulation capability. Thanks the FEM base technology, no addition mesh and couple calculation in Cast-Designer, one mesh for everything.
Simulation result Actual measurement results
Advance
module
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Deformation and compensation
73
The deformation simulation can provide accurate result of the part deformation after casting.
The deformation compensation function provides a simple way to correct the part geometry to have an accurate casting result.
Advance
module
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Distortion Compensation Solver
74
Advance
module
The deformation simulation can provide accurate
result of the part deformation after casting.
The deformation compensation function provides a
simple way to correct the part geometry to have an
accurate casting result.
(a) Full mould
(b) Hot tearing inducator
(c) Average normal stress
(d) Actual part with crack (after testing)
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Microstructure analysis result
75
Advance
module
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Distortion Compensation Solver
76
Advance
moduleDesigned casting Shape after casting
Original casting shape
After partcompensation
Casting compensation is a common and useful method to correct the casting distortion after casting, but ask rich experience, and very difficult for complex geometry.
A new Distortion Compensation Solver (DCS) was developed in Cast-Designer. With DCS, the user can simulate the part distortion and make geometry compensation automatically.
It is an iteration method to find the best geometry shape. Finally the adjustment distance of feature points could be reported and use back to CAD system.
This feature is unique in the market.
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Distortion Compensation Solver: Example
77
Advance
module
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Distortion Compensation Solver: Example
78
Advance
module
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Material Encryption
79
Support material encryption by user for the important material data The user can protect their material without addition license The others can use the material but could not read or edit the material
Encrypted material data
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Material Database
80
• More industrial level exothermic sleeve had been added to database
• Foseco
• Joymark
• Exochem
• ASK
• AMCOR
• Jodovit
• All above data are validated by simulation and experiment testing
• The data is encrypted.
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CFD Solver Parallel Performance (100K elements)
81
mesh size 100K 100K 100K 100K 100K
1Core 2Core 4Core 8Core 16Core
10% 325 270 215 202 212
20% 1613 1400 810 690 669
30% 3528 2993 1612 1277 1224
40% 6419 4983 2675 2048 1905
50% 9730 6986 3718 2748 2524
60% 13484 8984 4711 3498 3281
70% 17411 10757 5775 4361 4072
80% 20335 12406 6919 5299 4786
90% 22956 14348 8196 6420 5554
95% 24657 15422 9112 7235 6072
98% 26819 16762 10462 8058 6471
End
Hours 7.45 4.66 2.91 2.24 1.80
Original model V7.0
0
3600
7200
10800
14400
18000
21600
25200
28800
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
1Core
2Core
4Core
8Core
16Core
0.00
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
4.50
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
1Core
2Core
4Core
8Core
16Core
mesh size 100K 100K 100K 100K 100K
1Core 2Core 4Core 8Core 16Core
10% 1.00 1.20 1.51 1.61 1.53
20% 1.00 1.15 1.99 2.34 2.41
30% 1.00 1.18 2.19 2.76 2.88
40% 1.00 1.29 2.40 3.13 3.37
50% 1.00 1.39 2.62 3.54 3.85
60% 1.00 1.50 2.86 3.85 4.11
70% 1.00 1.62 3.01 3.99 4.28
80% 1.00 1.64 2.94 3.84 4.25
90% 1.00 1.60 2.80 3.58 4.13
95% 1.00 1.60 2.71 3.41 4.06
98% 1.00 1.60 2.56 3.33 4.14
End
Original model V7.0
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CFD Solver Parallel Performance (200K elements)
82
1 core 2 core 3 core 4 core I7_6700 8core 10core 16core 20core 32core 40core
12% 1210 925 532 252 113 83 70 92 52 61 73
15% 4812 2704 1840 1154 422 404 246 344 189 216 250
20% 9599 5297 3677 2593 857 1035 515 728 393 453 512
25% 15008 8522 5914 4269 1379 1792 859 1156 645 734 812
30% 21363 11808 8969 6307 2093 2671 1218 1618 927 1063 1192
35% 16408 12354 11601 3603 4239 1978 2744 1591 1604 1969
40% 14792 12726 4312 5307 2521 3264 1948 1932 2299
45% 17303 14752 5160 6527 2945 3899 2476 2298 2760
50% 17057 6331 7760 3435 4593 2934 2689 3228
55% 7637 9095 3969 5454 3427 3154 3767
60% 9354 10515 4584 6341 3942 3687 4284
65% 10940 11857 5292 7292 4423 4224 4772
70% 12674 13268 6042 8313 4907 4828 5509
75% 14411 14860 6802 9367 5424 5414 6097
80% 16125 16413 7624 10296 5977 5950 6652
85% 17963 17390 8466 11178 6445 6448 7249
90% 20076 18444 9445 12305 7095 7132 8013
95% 22197 21720 10860 13572 7929 8061 8915
98% 26839 25530 12665 15910 9226 9539 10718
0
3600
7200
10800
14400
18000
21600
25200
28800
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
1 core
2 core
3 core
4 core
I7_6700
8core
10core
16core
20core
32core
40core
0.00
0.50
1.00
1.50
2.00
2.50
3.00
0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
Orginal
8core
10core
16core
20core
32core
40core
The test machine was:
Intel Xeon CPU E5-2680
CPU in 2.8GHZ
2 Processors
20 physical core
40 logical core
64GB RAM
Windows 10 64 bits
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Full Chain of Casting Industrials
83
3D Part
DFM Check
Quotation
Prepare
Gating
System CAE Analysis
Manufacture
Production
1 2 3 4 5
3D Product
Gating System Design
Process Analysis
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Headache Problems in Casting Production
84
Thermal Balance: Smooth out hot spots, prevent soldering.
Do not over cool any portion of the die, maintain reasonable temperature
Uniformity across die surface (maintain flatness of part).
Begin to shorten cycle times without creating thermal extremes.
Monitor die / cooling line performance
Document die heat-up performance as a function of number of shots
Confirm simulation and solidification studies
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Existed Method: Thermal graphics from camera
85
Turn off cooling channel Turn on cooling channel
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What is Casting Production?
86
Casting Production is a special module in Cast-Designer to optimize the casting process to achieve the best productivity and cost rate, as well as the product quality.
Casting Production optimize the cooling channel and production cycle, to maintenance a reasonable mould temperature.
Casting Production can make a quick calculation of the production cost based on the optimized cycling time and user cost database. It could be used whatever the quotation stage for price estimation or the production phase for cost control.
Casting Production is fully automatic and very easy to use.
Advance
module
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Casting Production: example, gravity die casting
87
• For each iteration, the system will report the optimized result, such as the new mould opening time, mould closing time and total cycling time.
• Only 3 iterations, to reduce the cycling time from 110 sec, to 74 sec and finally 74.2 sec.
020406080
100120
75 58.5 59
33 3
77 7
25
5.5 5.2
to next cycle
Die closing
part ejection
Die opening
Cast-Designer CPI mesh model
Advance
module
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Define process layout and sensor list
88
Process layout Sensor list Sensor
Advance
module
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Cast-Designer Solution
89
3D PartDFM Check
QuotationPrepare
GatingSystem
ManufactureProduction
CAE Analysis(FEM + CFD7.2)
AutomaticOptimization
Cast-Designer
SavingCAST(Material)
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Cast-Designer Optimizer
90
Integration Optimization and Parametric studies Post processing
GUI
Task manager
Variables Results
Kernel for process management and data transfer –Integration tool
Cast-DesignerOptimizer
Cast-Designer Solvers(Thermal, Flow, Stress, Advance CFD)
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Different Applications in Casting Simulation
91
02 DOE (Design of Experiments)
To study a process window and its robustness so as to obtain a set of ideal parameters which provide good result inside an user defined goal.
03 Inverse (Curve fitting) From measured temperature, get the
material data or BC to apply to fit the output.
04 Robustness study Stochastic approach to check that
the given process is robust
For example, vary the furnace temperature within the known range to check that the process is robust enough to still give good parts
01 Optimization Optimize a given set of
parameters to achieve the best possible result based on goals to achieve
For example, to identify an ideal gating system, so as to obtain a balance flow to avoid gas entrapment also better shrinkage porosity.
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Cast-Designer Optimizer
92
Cast-Designer optimizer is the software for multi-criteria nonlinear optimization. The ideal solution for:
Improving performance
Searching for optimal management laws
Identification and verification
Cutting costs
Cast-Designer Optimizer is a unique software package opening up new opportunities for the market of “complex” practical problems.
It is used to improve the performance of complex systems, technical facilities and technological processes and to develop new materials based on a search for their optimal parameters.
The software also enables lower research expenditures and shorter implementation time. The main purpose of the system is to relieve a designer or researcher of the sufficiently complex and very labour-intensive process of searching for optimal system design parameters which simultaneously meet a great number of sometimes controversial requirements.
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Parallel Optimization with Multiple Criteria
93
Advantages:
• Maximum use of the potential of
multiprocessor system and local network.
• Efficient use of difficult-to-parallelise
applications and computation models
• Solution of complex problems which
have to present time been thought
impracticable to target.
Cast-Designer can support parallel automatic optimization now, this is a breakthrough
technology to reduce the lead time of optimization.
The user can use the same model for parallel automatic optimization, no any special setup but
one switch button. With this technology, the optimization calculation can speed up 5 to 10
times due to the model setup.
More ever, the restart function is also possible in optimization calculation. Means the user
can continue the last optimization run in any time.
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Shrinkage Porosity Optimization
94
D1
D2
Objective: optimize the riser diameter to have the best balance of the riser volume and
shrinkage porosity (accept level).
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Shrinkage Porosity Optimization
95
V=6360
V=4108
V=1697
V=2187
V: Volume of All Risers
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Shrinkage Porosity Optimization
96
V=6360
V=4108
V=1697
V=2187
V: Volume of All Risers
Safe line
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V=6360
V=6901
V=7609
Safe line
Optimized Zoom
V=1697
V=2187
Basic modeling30 min
Optimization setup1 hour
Optimization run
5 hours for 145 runs
CAST-DESIGNER V7.2
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Cast-Designer Solution
98
3D PartDFM Check
QuotationPrepare
GatingSystem
ManufactureProduction
CAE Analysis(FEM + CFD7.2)
AutomaticOptimization
Cast-Designer
SavingCAST(Material)
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Affordable Price
99
Affordable priceThe ROI is very clear. Now, you only spend a little cost like around one mould price and get the high-end design and simulation solution.
Ph.D.
CAE Specialists
Die Designer
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Conclusion
100
=
CAST-DESIGNER
3D Part
DFM Check
Quotation
Prepare
Gating
System CAE Analysis
Manufacture
Production
Thank you!
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