Rounding up casting process modeling: this rundown provides a brief review of the newest simulation software features available to metalcasters.Successful metalcasting facilities in the U.S. need effective and accurate simulation software Simulation software is based on the process of imitating a real phenomenon with a set of mathematical formulas. It is, essentially, a program that allows the user to observe an operation through simulation without actually running the program. to stay competitive, especially with increasingly fierce foreign competition. Ensuring a correct pour the first time is a top priority for metalcasters and customers alike. While most people in the industry would agree that software is necessary for success, it is not always easy to decide which software will provide the widest range of benefits. The single most important thing to keep in mind when making a selection is accuracy, not cost. Before selecting a program, it is important to analyze the needs of the facility. Software programs come in different packages for sand, lost foam, investment, ferrous, nonferrous and other specialized facilities. Consulting with others involved in the industry also can be beneficial. Software companies often are willing to give an in-plant presentation on their product. The next step involves assessing the complexity of the process itself, as well as the part being produced. Consider the complexity of the software necessary to meet those needs with success. In the past, modeling software could be judged using just two criteria, shrinkage and porosity prediction. Now the criteria are growing as rapidly as the modeling software programs are advancing and include at least the following: filter prediction, heat transfer prediction to determine shakeout time, metallurgical properties, and stress and strain. Programs that predict the minimum are no longer useful to most metalcasting facilities. The accuracy of these predictions is essential. Prediction criteria are not the only things that have changed in the past few years. For a top of the line product, you can expect to spend $100,000. Until recently, spending $50,000 in hardware was necessary to run the software, but now it can run smoothly on a quality PC. Cost includes more than just price. The software is as important as putting the right person on the job. Achieving maximum efficiency out of a program requires someone who is dedicated to learning the software and calibrating it to a specific operation, and willing to gain expertise and understand results. Engineering or metallurgical abilities also are useful. MODERN CASTING surveyed several companies offering solidification software. Following is a wrap-up of seven versions of casting process modeling relaying information about their features, as supplied by the software suppliers. Wincast Simtec Inc. 400 South State Street, Suite 110 Zeeland, MI 49464 Tel: 616/748-5647 Website: www.simtec-inc.com Email: info@simtec-inc.com Contact: Don Wade, general manager Newest Features--WinCast now has improved meshing capability that can handle large, thin-walled castings. It also has an improved simulated mold filling module for high pressure diecasting, low pressure permanent mold and tilt pour permanent mold. [ILLUSTRATION OMITTED] Software Features--Combined thermal-mechanical stress calculations and a built-in CAD package are two main features of this software. Engineers also can create files within WinCast or import from CAD files. Case History--WinCast is being utilized for a magnesium project. The focus of file project is on improving and optimizing the production of thin-wall castings and structural interior components. Simulation of the casting process and finite element analysis Finite element analysis (FEA) is a computer simulation technique used in engineering analysis. It uses a numerical technique called the finite element method (FEM). There are many finite element software packages, both free and proprietary. by WinCast was used to model the local distribution of mechanical properties and standard test procedures for further casting development. The project also will result in the establishment of a database of comprehensive process parameters for conventional casting alloys. This will provide optimized casting methods and a set of virtual design and test tools for magnesium casting for aeronautic aer·o·nau·tic also aer·o·nau·ti·cal adj. Of or relating to aeronautics. aer  o·nau applications.
Flow-3D Flow Science Inc. 683 Harkle Road, Suite A Santa Fe Santa Fe, city, Argentina Santa Fe, city (1991 pop. 341,000), capital of Santa Fe prov., NE Argentina, a river port near the Paraná, with which it is connected by canal. , NM 87505 Tel: 505/982-0088 Website: www.flow3d.com Email: info@flow3d.com Contact: Dave Souders, director of marketing and sales Newest Features Modeling moving parts Moving parts are the components of a device that undergo continuous or frequent motion, most commonly rotation. "Parts" only include the mechanical components which does not include fuel, or any other gas or liquid. coupled with flow analysis, microporosity prediction and thermal stress make up the latest features of Flow-3D Version 9.2. [ILLUSTRATION OMITTED] Software Features--Tru-VOF (volume of fluid) for accurate free-surface modeling, Favor used to define generic geometric regions within rectangular grids, multi-block meshing, defect tracking In engineering, defect tracking is the process of finding defects in a product, (by inspection, testing, or recording feedback from customers), and making new versions of the product that fix the defects. , and solidification and shrinkage are possible with Flow-3D simulation software. Case History--C.M. Taricco, Cueno, Italy, specializes in permanent mold making. The company pays close attention to the design process before making molds, actively cooperating with its customers' technical department during the design and metalcasting production phases. Taricco has found that the key to good design analysis is running flow and solidification studies to optimize the gating and risering system. Using the predictive capabilities of Flow-3D, Taricco has been able to identify hot spots hot spots acute moist dermatitis. , locate areas of probable porosity and resolve potential defects. Using the intelligence gained through a loop of design, simulation and analysis, Taricco has improved results for compressor sump bodies, valves and other similar parts. ProCast ESI (Edge Side Includes) A markup language for Web pages that enables elements of a Web page to be dynamically assembled in servers distributed throughout the Internet. Group 36800 Woodward Avenue, Suite 200 Bloomfield Hills, MI 48304 Tel: 248/203-0642 Website: www.esi-group.com Email: info@esi-group-na.com Contact: Kristi Kyne, sales and marketing coordinator Newest Features--ProCast now offers parallel processing parallel processing, the concurrent or simultaneous execution of two or more parts of a single computer program, at speeds far exceeding those of a conventional computer. , mechanical properties prediction of as-cast parts, a solidification module for SGI (SGI, Sunnyvale, CA, www.sgi.com) A manufacturer of workstations and servers, founded in 1982 by Jim Clark. The company was founded as Silicon Graphics, Inc., but changed to its acronym in 1999. , and process and geometry optimization. It also includes coupling with NVH/impact/structural analysis to display as-cast properties in an FEA (Finite Element Analysis) A mathematical technique for analyzing stress, which breaks down a physical structure into substructures called "finite elements." The finite elements and their interrelationships are converted into equation form and solved mathematically. model. [ILLUSTRATION OMITTED] Software Features--Other software features include an automatic, 3-D tetrahedral tet·ra·he·dral adj. 1. Of or relating to a tetrahedron. 2. Having four faces. tet mesh generator with a native CAD reader, a thermal solver with conduction, convection and radiation capabilities, a flow solver for sand erosion and turbulence, air entrapment entrapment, in law, the instigation of a crime in the attempt to obtain cause for a criminal prosecution. Situations in which a government operative merely provides the occasion for the commission of a criminal act (e.g. , misrun and cold shut prediction, and a stress solver for residual stresses, distortions, hot tearing, cracks and die fatigue predictions. Additionally, ProCast has advanced porosity modeling capabilities, microstructure mi·cro·struc·ture n. The structure of an organism or object as revealed through microscopic examination. microstructure Noun a structure on a microscopic scale, such as that of a metal or a cell predictions for phase formation and transformations, and grain structure modeling, and covers all casting processes. Case History--Citation Corp., Birmingham, Ala., designs, develops, and manufactures cast and machined components for the automotive, heavy truck, construction, agricultural and commercial industries. Recently, the company experienced difficulties in diecasting a thin-wall automotive housing that was producing a scrap rate of about 20%. Using ProCast software, engineers simulated the troublesome operation, finding that flow was slowed by an obstruction in the part. Moving the gates on the actual die eliminated nearly all scrap clue to nonfill, and the design change saved a minimum of $50,000 per year for machine time associated with empty cavities and defective parts, cost of re-melting defective parts, and inspection and sorting costs. NovaFlow & Solid NovaCast Technologies AB Soft Center S-372 25, Ronneby, Sweden Tel: +46 457/386 300 Website: www.novacast.se Email: info@novacast.se Contact: Hakan Fransson, system developer Newest Features--NovaFlow features Nova Stress for coupled thermal stress, 64-bit version release, a beta-tested volume of fluid scheme, automatic shrinkage calibration based on real-time ATAS ATAS Academy of Television Arts & Sciences ATAS Aboriginal Tutorial Assistance Scheme ATAS Air-to-Air Stinger ATAS Advanced Tank Armament System ATAS Active Towed Array Sonar ATAS Australian Tsunami Alert System ATAS Association of Turkish American Scientists thermal analysis Thermal analysis is a branch of materials science where the properties of materials are studied as they change with temperature. Techniques include:
adj. mush·i·er, mush·i·est 1. Resembling mush in consistency; soft. 2. Informal a. Excessively sentimental. See Synonyms at sentimental. b. zone non-linear approximation of thermo-physical properties, automatic low pressure, high pressure diecasting, gravity, tilt pour, investment, and gating and risering calculations. Software Features--Features of NovaFlow & Solid are automatic shrinkage calibration, advanced database based on a constitution diagram, air gap formation, cooling and heating channels, mold thermal cycling, mechanical property predictions, piston position controlled velocity, a velocity trigger for first- through third-phase intensification, a venting function for air bubbles, sensor functions and in-gate efficiency functions. Case History--Rani Metall AB in Sweden has been using NovaFlow & Solid as a standard tool for designing new models and production layouts since 1998. The company pours protection shields for an ABB n. 1. Among weavers, yarn for the warp. Hence, Noun 1. ABB - an urban hit squad and guerrilla group of the Communist Party in the Philippines; formed in the 1980s robot. Originally, defects appeared in and close to a machined screw hole. These defects resulted in high scrap rates after machining. After discussions with their customer, Rant decided on a change in design, as well as production layout. NovaFlow & Solid ensured precision with speed and effectiveness. SolidCast Finite Solutions Inc. 4769 Highland Park Highland Park. 1 City (1990 pop. 30,575), Lake co., NE Ill., a suburb of Chicago on Lake Michigan; inc. 1869. It is a retail business and medical center for the North Shore area. Drive Slinger, WI 53086-9441 Tel: 262/644-0785 Web site: www.finitesolutions.com Emaii: dave@finitesolutions.com Contact: David Schmidt, vice president Newest Features--SolidCast from Finite Solutions, Inc. has many new features, including an improved iron property calculator that can provide results over a wider range of chemistry and modulus valves. Another utility has been added to calculate appropriate heat transfer coefficients The heat transfer coefficient is used in calculating the convection heat transfer between a moving fluid and a solid in thermodynamics. The heat transfer coefficient is often calculated from the Nusselt number (a dimensionless number). for mold coatings, air and water cooling Water cooling is a method of heat removal from components. As opposed to air cooling, water is used as the heat transmitter. Water cooling is commonly used for cooling internal combustion engines in automobiles and electrical generators. channels and radiation and convection from hot surfaces. Additionally, the speed of SolidCast simulations, meshing, view factor calculations and shell creation functions have increased 20%. Software Features--Features for the software also include improved file save functions, a new training workbook with updated instructions on how to use the calculator utility, and a movie-making feature with improved picture quality. The new wmv format is supported by recent versions of Windows Media Player Digital jukebox software for Windows from Microsoft that plays a variety of audio, video and streaming formats including MP3, WMA, CD audio and MIDI. Starting with Version 6.2 in 1999, the Windows Media Rights Manager was added for securing copyrighted content. . Simulation settings previously requiring manipulating files in the Solidcast folder can now be adjusted more easily. Settings include reduce mold/metal heat treat coefficient at solidus point for permanent mold; thermal center feeding for riserless iron castings; low pressure simulation; SolidCast fill tuned for horizontal; SolidCast tuned for vertical; and thermocouple time step save increments. CapCast EKK EKK Eberswalder Karneval Klub (German: Eberswalder Carnival Club) Inc. 37682 Enterprise Court Farmington Hills Far·ming·ton Hills A city of southeast Michigan, an industrial suburb of Detroit. Population: 81,400. , MI 48331 Tel: 248/624-9957 Web site: www.ekkinc.com Email: ekk@ekkinc.co Contact: Ken Siersma, software engineer Newest Features--EKK Inc. has incorporated North American North American named after North America. North American blastomycosis see North American blastomycosis. North American cattle tick see boophilusannulatus. Die Casting die casting Forming metal objects by injecting molten metal under pressure into dies or molds. An early and important use of the technique was in the Linotype machine (1884), but the mass-production automobile assembly line gave die casting its real impetus. Association gating design methodology into its software, allowing machine capability to be correlated to gating design and casting quality. Automatic variable mesh density can be tested for fine mesh in casting and mold surface and coarse mesh in mold away from the casting. Other new features include trapped air and porosity growth models and a moving shot sleeve analysis with a casting cavity. [ILLUSTRATIONS OMITTED] Software Features--Capcast is a complete casting simulation software package that includes automatic finite element See FEA. meshing, fluid flow, solidification, stress, microporosity and post processing capabilities. Case History--A North American die casting manufacturer launched five new large-scale, multiple-cavity productions last year. All five productions were extensively studied during development of the tooling using Capcast simulation software, which led to successful launches in each case. Magmasoft Magma Foundry Technologies 10 N. Martingale martingale a leather strap running from the girth to the reins or the noseband for the purpose of restricting the movements of the horse's head. There are many designs. The common ones are the standing martingale, which is attached to the noseband, and the running martingale, which Road Suite 425 Schaumburg, IL 60173 Tel: 847/969-1001 Website: www.magmasoft.com Email: info@magmasoft.com Contact: Christof Heisser, president Newest Features--Magmasoft now includes autonomous optimization, micromodeling and gas porosity Abstract Determining the true porosity of a gas filled formation has always been a problem. While gas is a hydrocarbon, similar to oil, the physical properties of the fluids are very different, making it very hard to correctly quantify the total amount of gas in a formation. prediction in nonferrous alloys, as well as core and moldmaking simulation. [ILLUSTRATION OMITTED] Software Features--Magmasoft can be used for filling defect filling defect n. A defect in the contour of part of the gastrointestinal tract, as seen by x-ray after contrast medium has been introduced, indicating the presence of a tumor or foreign body. prediction, including venting and entrapped air prediction, solidification defect prediction, cooling and shakeout, shrinkage and microporosity prediction, microstructure, mechanical properties, heat treatment, residual stresses and distortion in refinement, support of die-life prediction and finite element analysis, and application programming interface. It is multi-core and cluster capable and works with CAD interfaces. Case History--Glidewell Specialties Foundry Co., Calera, Ala., used an entry-level casting simulation tool for several years. However, some newly quoted castings required a more sophisticated approach, as Glidewell wanted to use as few risers as possible. Wall-thickness and molding conditions appeared to be just right, but only a simulation tool with micro-modeling capabilities, considering the specific solidification conditions for the iron composition used in the castings, would be able to help Glidewell find the optimal combination of chill placement, feeding aids and gating design. Glidewell decided to take on one seat of Magmasoft and MagmaIron. Different pouring orientations and gating systems were evaluated in Magmasoft, clearly showing the benefits and drawbacks of each approach. Afterwards, one of the castings ended up riserless. All three castings were poured as simulated in Magmasoft. All parts passed the ultrasound test. A MODERN CASTING Staff Report |
|
Printer friendly
Cite/link
Email
Feedback
Reader Opinion