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Steps in Simulation - Overview
Select Materials: Casting Alloy, Mold Materials,
Boundary Conditions
Create a 3D Model: Import STL files from CAD
or create 3D shapes within SOLIDCast
Mesh the model
Run a simulation:
Use FLOWCast filling
Use SOLIDCast filling
No Filling
Plot simulation results
Decide whether to redesign/rerun the
simulation or not
Types of Simulation
Naked Casting for design of risers and
gating
Iron Castings (Grey & Ductile)
Other Alloys (Steel, Aluminum, etc.)
or
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.
Permanent Mold Casting Simulations, Contd
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.
Starting
SOLIDCas
t
Menu
Project Tree
Welcome to the
SOLIDCast start
screen
Creating
a New
Model:
Naked
Casting
Simulation:
Steel
From the Menu, select
File New Model
For the first model,
SOLIDCast will ask
you to enter a Project
Name
Tool Bar
Saved with Fine Tolerance: 104,612 Saved with Coarse Tolerance: 29,942
Triangles Triangles
Back to
our
Casting
Model
After closing the Add Shape window, we
can control our view of the model by using
the viewing controls on the Tool Bar.
Select Zoom Full to enlarge the model
image
so that it now occupies most of the
screen.
Note that by default we are in the XZ view.
We can select the YZ View to see a side
view.
The XY View shows a top down view looking
from above.
By selecting the Free Rotating Isometric View we can
rotate the model by holding down the left mouse button
and moving the mouse.
Creating
the Mesh
Before we run a simulation, we need to create a Mesh. This
is done from the Model menu by selecting Create Mesh.
Here we enter the mesh parameters and then click OK.
The system generates the mesh. First the casting model is
meshed
layer by layer.
And then the mold around the casting is meshed (if you
have specified mold material as part of the meshing
operation).
When meshing is complete, you will see a Mesh entry on
the Project Tree.
Some Comments About Meshing
The more elements (Nodes) in a mesh, the longer the
simulation will take to run.
Chvorinovs Rule:
t = B (V/A)2
(V/A) is referred to as
the Casting
Modulus
Casting sections with
low modulus solidify
Casting sections
first. with
high modulus solidify
last.
Basics of Riser Design
Increasing
Modulus
Primary Rules:
1. The riser should have a higher
modulus than the part of the
casting its attached to.
2. The riser must have sufficient
volume to
feed the contraction which
occurs during cooling and
solidification.
We begin by selecting Riser Design Wizard from the
Simulation menu.
We can modify the Sensitivity setting for either heavy or
light section castings, then click the Next button.
The Wizard has identified 3 Feed Areas (zones) within this
casting.
To visualize Zone 1, we select it and also select Plot Feed
Area, then click Next.
This allows us to select the Type of plot. Generally, an Iso-
Surface plot is most useful.
Maximum Modulus
(inches)
Actual
Modulus of
given riser
Naked Casting
Simulation:
Ductile Iron Casting
Iron Casting Simulation
The objective in this exercise is to determine the
properties of the cast iron so that we can calculate
the required size of the riser and contact.
Cast iron differs from steel in that it undergoes an
expansion phase as graphite precipitates during
solidification
We need to know the Modulus of the casting, its
chemistry and temperature and the rigidity of the
mold as well as the quality of the iron in order to know
when expansion will begin and how much contraction
and subsequent expansion of the iron there will be.
By running a simulation of the naked casting we can
determine the casting Modulus
Knowing this information and the casting weight, we
can determine a correct riser design for the casting.
Iron Castings General Design Rules
Risers should be "hot", meaning that gates should be
connected to risers in order to ensure that they are
filled with hot metal. If this is physically impossible
given the arrangement of the castings in the mold,
then exothermic sleeves should be used to prevent
"cold" risers.
Sizing gates to ensure that they solidify earlier than the casting.
t = A/3
Suggested Runner Sizing
Model of Completed Design
This shows the final complete mold design for production of the
casting, with one riser per casting (in this design, the risers are
sleeved).
Running a Full
Simulation
Full Simulation:
Stainless Steel
Sand Casting
As before, we start SOLIDCast with a blank screen.
We select File New Model from the menu.
The system asks us to enter a new Project Name.
Now we have a new project started. Click the Add Shape button
on the tool bar.
We will add an STL shape. Click the File button.
Select the STL file and then click Open.
Click the Add Shape button.
The casting shape appears. Click the Close button in the Add
Shape window.
The Add Shape window closes.
From the tool bar, select Zoom Full.
Again from the tool bar, select the Free Rotating Isometric View.
This allows you to rotate the model. We can see that this is a
complete model with castings, risers and gating.
Now to select the materials, select Model Materials List.
On the Casting Material window, click From DB
The alloy for this casting is 316 stainless steel. Select this alloy
from the database list, and click Use This Casting Material.
The alloy is now 316 SS.
We can set the Pouring Temperature by changing the Initial
Temperature entry.
This shows the cooling and shrinkage (contraction) curves.
Under Mold Materials we already have Silica Sand.
Internal HT Coefficients are turned off.
Finally, on the Other tab we set the pouring time, which is 10
seconds.
Now, on order to perform a filling simulation we need a shape of
Fill Material which contacts the top of the sprue.
Click the Add Shapes button on the tool bar.
Under Shape Type, select Solid Cylinder Z. This is a cylinder
whose axis is vertical.
Now a Solid Cylinder Z is selected.
Under Material, select Fill Material as the type of material.
We need to enter the coordinates at the top center of the sprue.
This will be the bottom center of the Fill Material shape.
By clicking with the mouse on the top center of the sprue shape,
the coordinates are automatically filled in for us.
Now we enter a length (thickness) and a radius. The thickness
MUST be more than the Node Size, and the radius should define a
circle which is somewhat larger than the incoming metal stream.
Now click Add Shape and the Fill Material shape appears.
We can take advantage of the fact that this model is perfectly
symmetrical about the center line. We can add a Plane of
Symmetry so that only one half of the model needs to be
simulated; this will cut the simulation time in half.
To do this, we select Model Options
The tab at upper left shows that we are defining Planes of
Symmetry.
Select a Lower X Plane of Symmetry, at default location 0.
Now click Apply and then OK.
A Plane of Symmetry is now active.
Now we can mesh the model. Select Model Create Mesh
Enter the Mesh Parameters and click OK
On the first pass, the casting model is meshed. Note that only
one-half of the model is actually meshed due to the Plane of
Symmetry.
On the second pass, the mold is meshed.
When meshing is finished, we select Mesh Start Simulation
Note that, when Fill Material is included in the model, we have a
choice of Fill Algorithms. We will select FLOWCast Full.
Now we click Run Sim to start the simulation.
FLOWCast now starts running a flow model to
simulate mold filling, start at the Fill Materials.
By selecting the Filling tab, we can select some
parameters as to how data is stored for later
viewing or video creation.
In this example, we are saving Full data every
10%, and temperature data every 0.4%.
Now we return to the Display tab.
At the Display selection at the top of the screen,
we can choose to display metal velocity rather
than temperature.
When temperature is displayed, we can choose to
display the range from pouring down to liquidus
(Liq-Max)
Or from pouring down to solidus (Sol-Max)
Filling continues until the mold is 100% full.
After filling simulation, the cooling and solidification of the casting is
simulated by SOLIDCast.
When the solidification simulation is complete, the system returns
to the SOLIDCast screen.
We can turn off the display of the Plane of Symmetry by selecting
Show Planes of Symmetry and un-checking this selection.
The Plane of Symmetry is no longer shown.
Now we open the simulation by double-clicking the Simulation
entry on the Project Tree.
With a Plane of Symmetry, only half of the model was simulated.
By selecting Simulation Mirror Results the simulation results are
mirrored into the other half so that the entire model can be
plotted.
This selection display a warning message. Click OK to proceed.
Now we can plot the simulation result data. We start by selecting
Simulation Plot Iso Surface.
Under Data Type we select Critical Fraction Solid Time.
The Max and Min values are shown.
We start by plotting a value close to the Max.
This shows the area that is hotter than CFS at 13 minutes. This
metal is liquid and can flow. Metal colder than this cannot flow.
Now we select a lower number to plot.
This shows the liquid metal at 9 minutes. We are stepping
backward in time to see the progression of solidification as
measured by Critical Fraction Solid Time.
Again, a lower number is entered.
The liquid metal at 6 minutes is displayed. What we are looking
for is isolated hot spots where shrinkage porosity may form.
A value of 3 minutes is entered.
These are all the areas that were liquid at 3 minutes.
2 minutes is entered.
These areas were liquid at 2 minutes.
An alternate method of viewing progressive solidification is to use
the Tools QuickPlot function.
Select the simulation and click Start Plotting
By default, a temperature plot is displayed.
We select Critical Fraction Solid Time as the Data Type.
Critical Fraction Solid Time is displayed.
We select Show areas below Min as transparent.
Now, by moving the Min slider bar
we can easily plot Critical Fraction Solid at various values
which gives us an easy way to watch the progressive
solidification of the casting.
When were done with this plot, we click the Quit button.
Now we select Plot Iso-Surface again
and this time select Material Density. This is an indicator of
shrinkage (macroporosity) based on lack of feeding in isolated hot
spots.
A value of 0.99 is typical. This shows areas which have 1% void
or worse, which are usually considered severe.
Now we can see areas of expected shrinkage porosity in the
casting.
Using the XZ View
the YZ View
or the XY View allows us to locate the predicted defects exactly.
Another type of plot is the CastPic Plot
Again we select Critical Fraction Solid Time as the Data type.
Click OK to plot the default Max and Min.
This gives a picture of progressive solidification in the casting.
By lowering the Max plot value and selecting Plot Out of Range
Data
we can more clearly differentiate areas that solidified first and
last.
Here we are plotting Material Density and specifying a Cut Plane
in the Z direction at Z = 3.8
This shows a 3D image of the casting where the shrinkage defects
are clearly visible as dark blue areas.
By changing the location of the Cut Plane
we can show shrinkage indications in different areas, still as a
3D image.
Priority Numbers
Overlap Region
If two shapes do not overlap,
the Priority Numbers dont
matter.
Full Simulation:
Investment Casting
As before, we start SOLIDCast with a new project.
Select File New Model
Enter 1500A01 as the Project Name and click OK.
For this session we will import a Component File. Select Model
Import and click on SOLIDCast 5.x Component File.
The Component File name is 1500A01. Select it and click Open.
Accept the default (0,0,0) offset by clicking OK.
The model appears. It is red because it is selected.
Double-click next to the model to un-select it.
With the Free Rotating Isometric View we can rotate the model.
To create a shell around this model, we need an STL file which
contains the model shape.
We can create an STL file from our model by using the Tools menu.
Select Tools STL from Model
Select the model in the window (in this project there is only one
model) and click Create STL File.
Enter a name for the STL file and click Create STL File.
Now select Tools Create Shell
Around STL Shape.
Navigate to the STL file which was just created, select it and click
Open.
Now we enter the shell thickness, the surface quality, open or
closed top and the name of the STL file which will contain the
shell shape.
The program runs Pass 1
and then Pass 2.
and then displays the number of triangles in the STL file just
created.
Now from the Add Shape button we select STL file and click the
File button.
Navigate to the STL file containing the shell, select it and click
Open.
Note we select Invest Shell as the Material Type, and set the
Priority Number to 8.
Now click Add Shape.
The shell appears around the casting. Click the Close button.
Now we need to add a Solid Cylinder Z for the Fill Material.
Click on the top center of the pour cup to set X, Y and Z. Select
Fill Material as the Material Type. Note that we set the Priority
Number to 4. Click Add Shape.
Note that if we select Show Planes of Symmetry, this model
already has a Plane of Symmetry set as a Lower-X Plane at X=0.
Now we mesh the model. Select Model Create Mesh.
Note that for Mold Type we now select None. This is because the
mold (the shell) is already part of the model.
The model is meshed.
After we mesh the model, we need to run
the View Factor Calculation to take into
account radiant heat exchange between
different surfaces of the shell.
On the Project Tree, select the Mesh. Then from the menu select
Mesh View Factor Calculation.
The View Factor Calculation runs.
Now we start the simulation by selecting Mesh Start Simulation.
Select FLOWCast Full as the Fill Algorithm, then click Run Sim.
The simulation will start
running.
When the simulation is complete, select the Simulation on the
Project Tree, then select Simulation Mirror Results.
Select OK to mirror the simulation result data on both sides of the
Plane of Symmetry.
Note that our view shows the shell. To view the cast material,
select Show Show Report.
Now the casting and gating are displayed.
To view the pattern of solidification, select Simulation CastPic
Plot.
Select Critical Fraction Solid Time as the Data Type, and specify a
Y Cut Plane at 0 to see the sectioned center plane of the casting.
This shows the pattern
of solidification. Note
that the last point to
solidify is in the center
of the casting. This is
not desirable; the last
point of solidification
should be in the gating
or risers, not in the
casting.
Now we plot the predicted shrinkage. From the menu select
Simulation Plot Iso Surface.
Select Material Density as the Data Type, and enter 0.99 as the
value to plot.
This shows an X-ray view of predicted shrinkage. There is severe
shrinkage at the top center of the casting. This gating system
needs to be redesigned.
Example 5
Full Simulation:
Permanent Mold Tilt
Pour Casting
As before, we start SOLIDCast with a new project.
Select File New Model to start a project.
SOLIDCast will ask for a Project Name. Here we enter 6064
(the part number) and click OK.
Now we have a blank model space in Project 6064.
Lets begin by selecting the casting alloy and mold materials.
Select Model Materials List.
The Casting Material will be the first selection. Click From
DB to open the Casting Material Database.
In the database we select Al 356.0 as the casting alloy. Click
Use This Casting Material.
Click Yes to confirm that this is the casting alloy.
The alloy properties are shown.
Lets change the Initial Temperature (the pouring
temperature) to 1360 F.
These are the cooling and shrinkage curves. We note that
the Niyama Point is set a 35% solid; it should be 99% for this
alloy. Click Set Niyama Pt to change this
Move the mouse to 99% Solid and click one time to set the
Niyama Point.
Now select the Mold Materials tab. Our mold is steel, so we
want this to show up on the list. Click the From DB button.
Select Steel from the list and click Add to Materials List.
Click Yes to confirm.
Now, on the list window click Steel.
Its properties are shown. The Initial Temperature is 400F.
Generally, for permanent mold simulations we may want to
set the temperature close to the assumed operating
To do this, we just type 850 in the Initial Temp field.
Now we want to set Internal Heat Transfer Coefficients. This
is important in permanent mold because the mold and alloy
have high thermal conductivity and the surfaces between
First, click the selection which says Use Internal Heat
Transfer Coefficients.
Now, between Casting and Riser (which is not a real surface)
we enter a high number like 10000.
Between Casting Material and Ambient we enter 1.5, which
takes into account external radiation and convection loss.
Between Casting Material and Steel we enter 200, which
accounts for the coating on the casting surface of the mold.
Between Riser Material and Casting Material weve already
set the HTC.
Between Riser Material and Ambient we set the HTC to 1.5.
Between Riser Material and Steel we set the HTC to 125,
which reflects a heavier mold coating on the riser surfaces.
Between Ambient and Casting Material weve already set the
HTC.
Between Ambient and Riser Material weve already set the
HTC.
Between Ambient and Steel we set a HTC of 8, which
represents heat loss due to radiation and convection at the
outer surface of the mold.
Between Steel and Casting Material weve already set the
HTC.
Between Steel and Riser Material weve already set the HTC.
Between Steel and Ambient weve already set the HTC.
Now we click the Other tab and set the Ambient Temperature
(in this case 90F) and the Pour Time, which in this case
represents a 15 second tilt time.
Now lets add the shapes to the model. Click Add Shape on
the Toolbar.
This opens the Add Shape window. STL file is the default
shape type.
Click the File button to start browsing for the STL files to
import.
Here we select the casting shape and click Open.
Set the Material type to Casting Material and the Priority to 5.
Click Add Shape and the casting appears.
Now click the File button again, select the riser file and click
Open.
Set the Material type to Riser Material and the Priority to 6.
Click Add Shape and the risers appear.
Now click the File button again, select the mold file and click
Open.
Set the Material type to Steel and the Priority to 7.
Click Add Shape and the mold appears. (Note: The mold
shape in this case is a solid block with no cavity. The Priority
numbers will ensure that the casting and riser shapes will
Now click the File button again, select the Fill Material file and
click Open.
Set the Material type to Fill Material and the Priority to 4.
Click Add Shape and the Fill Material shapes appear.
Now we have the complete model loaded.
Click the Zoom button on the Toolbar and select Zoom Full.
The model enlarges on the screen.
Now click the Free Rotating Isometric View button.
You can rotate the model by holding down the left mouse
button and moving the mouse cursor across the screen.
Now we want to set the tilt pour parameters. Select Model
Options from the menu.
Click the Tilt Pour tab.
This window controls the tilt pour direction and start/stop
angles.
Click Tilt pour enabled
The Start angle should be set to 270, the Stop angle to 0, and
Rotate about X should be selected. Click Apply and then
OK.
Now we will mesh the model. SOLIDCast allows us to use a
Coarse mesh to simulate initial cycles to heat up the mold,
and then a Fine mesh to simulate the final steady-state
cycle. Select Model Create Mesh from the menu.
Here weve entered the name Coarse Mesh and specified
2.5 million nodes. Note that None is selected for Mold Type
because the mold is already part of the model.
The coarse mesh is created.
Note that on the Project Tree we have a Coarse Mesh entry.
Now lets create the fine mesh. Select Model Create Mesh
again from the menu.
Here weve entered the name Fine Mesh and specified 5
million nodes.
The fine mesh is created.
Now we have both coarse and fine mesh on the Project Tree.
Its almost time to start the simulation.
Before we start the simulation, lets make sure that System
and Simulation parameters are set correctly. Select Tools
System Parameters from the menu.
Make sure that Volumetric Calculation Interval is set to 10.
Click OK.
Now click Tools Simulation
Parameters.
Make sure that there is a check next to Reduce Mold/Metal
HT Coefficient at Solidus Point. This causes the system to
simulate the small gap that occurs at the casting surface
when the metal solidifies. Click Apply and then Exit.
Now were really ready to start the simulation.
On the Project Tree, select and highlight the fine mesh.
From the menu, select Mesh Start Simulation.
The Start Simulation window appears.
For Simulation Type, select Permanent Mold. For Fill Algorithm, select FLOWCast Full.
For Warm-up Mesh, Select Coarse Mesh. For Warmup Fill Algorithm, select FLOWCast
Full also. For Auto-cycle count, enter 3. This indicates that the system will run three
total cycles, two with the coarse mesh (to heat the mold to steady-state condition)
and the final with the fine mesh. The Mold Open Time is set to 30 seconds; this
indicates the amount of time the mold stays open after one casting is ejected before
the next one is poured. After making all these selections, click Run Sim.
The first filling simulation runs in FLOWCast using the coarse
mesh.
The first solidification simulation runs in SOLIDCast, also using the
coarse mesh.
The second filling simulation runs in FLOWCast, again using
the coarse mesh.
The second solidification simulation runs in SOLIDCast, also using the
coarse mesh.
The third filling simulation runs in FLOWCast using the fine
mesh.
The third and final solidification simulation runs in SOLIDCast using
the fine mesh.
Once all simulations are complete, the system returns to the
Model View.
Double-click the Simulation entry on the Project Tree to
starting viewing results. The Simulation Status window
appears. Click the Close button.
From the menu, select Show Show Report.
This hides all mold materials and shows only Casting and
Riser material.
By pressing the + key we can enlarge the image.
One way to plot results is by using Iso-Surfaces. From the
menu, select Simulation Plot Iso Surface.
Under Select Data Type pick Critical Fraction Solid Time.
You can also select a color for the Iso-Surface by clicking
Color Here we are selecting yellow as the color.
Note the Min and Max values for Critical Fraction Solid Time
at the right. Lets enter a value of 1 under Plot This Value,
which is about half way between. Now click OK.
This shows the metal that was above the CFS point
(essentially, liquid metal) at 1 minute after pouring.
From the menu, select Simulation Plot Iso Surface again.
This time well plot 0.75 minutes.
And this shows the metal which was above CFS at 0.75
minutes after pour. By plotting different values we can see
how the casting solidified.
A different and easier way to watch the casting solidify is to
select Tools QuickPlot from the menu.
In the window, select the Simulation you want to plot and
click Start Plotting.
The model is shown initially with colors indicating
temperature.
Lets change the View to XZ.
This shows an orthogonal XZ view of the casting and risers.
By clicking the L-R-U-D buttons we can slightly change the
view. Here we have clicked R three times and D three times.
Now lets select Critical Fraction Solid as the Data Type.
Finally, under Display Type select Show areas below Min as
transparent
Now by moving the Min slider bar or by clicking the arrows on
the sides of the bar, we can get an animated picture of the
progressive solidification of the casting and risers.
Here weve slid the bar a little further to the right
and now we see clearly that an isolated hot spot has
formed in the center of the casting. This usually indicates the
potential for shrinkage porosity. Click Quit to exit from
To predict the potential for macroporosity, select Simulation
Plot Iso Surface from the menu and select Material Density
as the Data Type.
Here we have entered 0.995 as the value to plot.
This indicates a potential for shrinkage porosity in the
casting, at the location of the central hot spot.
Process Optimization
Using OPTICast
Weve seen solidification analysis, mold
filling and fluid dynamics. 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?
What do we mean by
OPTIMUM?
Foundry Engineer
Process
Revised
Simulation
Design
System
Simulation Results
Not
Acceptable? Acceptable?
Decide
Done What to
Change
Foundry Engineer
A new paradigm
Initial
Design
Foundry Engineer
Process
Revised
Simulation
Design
System
Simulation Results
Not
Acceptable? Acceptable?
Decide
Done What to
Optimization
Change
Engine
The Layered System Approach
Optimizing
Engine
Casting Process
Simulator
Design Variables
Constraints
An Objective Function
3) Launch the Optimization
Design Variables
Was an
optimum
Run a Simulation
value of the
with
Objective
Function
achieved?
Examine
Results No/Yes
DONE
The Optimization Engine evaluates Response Surfaces.
Requirements of the Modeling System for
Application of Optimization
Casting Weight
Yield =
Casting + Riser Weight
Were specified
that ONLY the
horizontal
dimensions of the
pour cup can vary;
its height stays
constant.
The gate is selected as
Design Variable #3.
Shrinkage in No
Casting Shrinkage in
Casting