Macro Scale Casting Simulation with STAR-Cast J.Gnz CD-adapco - - PowerPoint PPT Presentation

▶
macro scale casting simulation with star cast
SMART_READER_LITE
LIVE PREVIEW

Macro Scale Casting Simulation with STAR-Cast J.Gnz CD-adapco - - PowerPoint PPT Presentation

May 12, 2023 99 likes •320 views

Macro Scale Casting Simulation with STAR-Cast J.Gnz CD-adapco Casting Systems Product requirements increase: Less weight Higher efficiency Time to market decreases Casting processes must be adopted Simulation to

slide-1
SLIDE 1

Macro Scale Casting Simulation with STAR-Cast

J.Gänz – CD-adapco

slide-2
SLIDE 2
  • Product requirements increase:
  • Less weight
  • Higher efficiency
  • Time to market decreases
  • Casting processes must be adopted
  • Simulation to aide manufacturing goals
  • Understand and optimize the casting

process

  • Enhance product quality
  • Rising demands require evolving

simulation methods

Casting Systems

slide-3
SLIDE 3

Simulation Scope

Physics

  • Co-Simulation
  • Transient effects
  • Multi-Scale Simulation

System

  • Geometrical detail
  • Entire production process
  • Boundary Conditions

Pouringsimulation; Courtesy of TiTal Macro to Micro-Scale Simulation using MICRESS

slide-4
SLIDE 4

Characteristics

  • Permanent mold process
  • Highly controllable process
  • Filling driven by applied pressure field

Advantages of low pressure casting:

  • Smooth filling also for complex geometries
  • Dense microstructure (reduced porosity)
  • Improved material properties can reduce casting

volume

Counter Pressure Casting (CPC)

slide-5
SLIDE 5

Counter Pressure Casting

Source: http://www.cpcmachines.com

CPC-facility at the ACCESS- Techcenter

slide-6
SLIDE 6

Counter Pressure Casting

Fill the mold by increasing the pressure in the furnace chamber

Source: http://www.cpcmachines.com

slide-7
SLIDE 7

Counter Pressure Casting

Let part solidify at high pressure to reduce porosity

Source: http://www.cpcmachines.com

slide-8
SLIDE 8

Counter Pressure Casting

Reduce pressure and detach melt from part

Source: http://www.cpcmachines.com

slide-9
SLIDE 9

Macro Scale Simulation of the CPC Process

Simulation requirements:

  • Capture the mold filling accurately

– Furnace pressure drives mold filling

  • Phase change modelling

– Thermal – Mushy Zone

  • Defect Prediction
  • Accurate initial conditions
  • Die cycling
  • Capture geometric details
slide-10
SLIDE 10

Die Cycling

Close die Close die Filling Filling Solidification Solidification Open die Open die Cool down Cool down Removing casting Removing casting spraying die parts spraying die parts Drying die parts Drying die parts

Multiple Multiple Multiple Multiple casting casting casting casting cycles cycles cycles cycles to to to to reach reach reach reach „ „ „ „steady steady steady steady state state state state“ “ “ “ thermal thermal thermal thermal conditions conditions conditions conditions Simplified Simplified Simplified Simplified mold mold mold mold filling filling filling filling Pure thermal Pure thermal Pure thermal Pure thermal simulation simulation simulation simulation

slide-11
SLIDE 11

Die Cycling – Results

1 2 3

slide-12
SLIDE 12
  • Dedicated tool for Casting Simulations

– Casting User Interface – Process driven setup – Single environment

  • CAD to post processing
  • Key Features:

– Multiphase (VoF) Filling & Solidification – Criteria Functions for Defect Prediction – Material Database

  • CAD to Mesh

– Native CAD import – Multi-Region Imprinting – Shell Generation Tool – Automated Polyhedral Meshing

  • Prismatic Boundary Layers

STAR – Cast

slide-13
SLIDE 13
  • Best of both worlds

– Provide state of the art of casting simulation solution by combining the engineering experience of two companies which have a long-standing track record in providing CAE solutions and casting processes for over 25 years – Established casting solution STAR-Cast

Strategic Partnership

slide-14
SLIDE 14

Workflow Demonstration CPC

slide-15
SLIDE 15

Casting of a Tire Rim

Pressure Outlet Rim: A356, Casting Temperature: 680 degC Die: XCr38V1 @ 350 degC

slide-16
SLIDE 16

Geometry preparation

  • 2 Hours

Geometry preparation

  • 2 Hours

Meshing

  • 2 Hours (~1.4 Mio Cells)

Meshing

  • 2 Hours (~1.4 Mio Cells)

Physics Setup

  • 1 Hour

Physics Setup

  • 1 Hour

Simulation Run

  • 72 hours on 48 CPU’s

Simulation Run

  • 72 hours on 48 CPU’s

Tire Rim – Simulation Workflow

slide-17
SLIDE 17

Results

slide-18
SLIDE 18

Thank you

slide-19
SLIDE 19
  • Fully transient simulation
  • Immiscible Fluids: VOF model
  • Simultaneously solving for flow and energy:

– Resolution of the filling front – Gas phase resolved via VoF model – Phase change – Conjugate heat transfer

Multiphase Simulation

slide-20
SLIDE 20

A dedicated Material Database is available in STAR-Cast, pooling all relevant material information for the casting engineer

Material Database

slide-21
SLIDE 21
  • Aim is to provide additional information on

the quality and structure of the casting

– Shrinkage – Macro/ Micro Porosities – Primary/Secondary Dendrite Arm Spacing

  • Available Models

– Criteria Functions – Macro Porosity Model

Defect Prediction

centre line porosity Ref: Access, STAR Ref: Access, STAR Ref: Access, STAR Ref: Access, STAR-

  • Cast

Cast Cast Cast