ProCAST General Presentation

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Shortening the product part development time

Overall process improvement

Reducing product cost Casting design optimisation

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– Improper mould filling in a multi-cavity steel die

– Gas porosity problem

• Case Study 3 – Al HPDC

– Improper mould filling in a multi-cavity steel die

• Case Study 4 – Steel Investment Casting

– Gas and shrinkage porosity were observed in the initial design of the cast freight trailer component.

• Case Study 5 – Steel Sand Casting

– Primary & secondary shrink porosity in critical areas

• Case Study 6 – Steel Sand Casting

– Improving yield by reducing pouring weight

– Reducing machining cost

• Conclusion

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ProCAST is the leading FEM foundry simulation software, which provides coupled thermal-flow-stress analysis, along with

unique metallurgical capabilities, for all casting

processes and castable alloys.

• Proven Success of ProCAST 2005 Helps ESI Group Pick Up

2006 Frost & Sullivan European Technology Leadership of the Year Award

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Modular Program

Courtesy of FOMET SpA, Italy

Al Tilt Gravity Die Casting

Courtesy of ACTECH GmBH, Germany

Al Sand Casting

Ni NGV Investment Casting

Courtesy of Kovolis Hedvikov Czech Republic

Al High Pressure Die Casting

Courtesy of MAN, Germany Cast Iron Sand Casting

Al Direct Chill Casting Courtesy of CMS, Turkey

Al Low Pressure Die Casting

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ProCAST In Action

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Geometry & Meshing

• Utilises the Finite Element Method (FEM)

– Most accurate geometry description and analytic procedure

• Easy to import geometry from all CAD systems

– Accepts: - One of the following CAD file format:

• Acis Native (.sat) file

• Cadds Native (.pd) file

• Catia Native V4 (.model, dlv, exp)

or V5 (.catpart) file

• Pro-Engineer Native (.prt) file

• SolidEdge Native (.par) file

• SolidWorks Native (.sldprt) file

• Unigraphics Native (.prt) file

• VDA Native (.vda) file

– Or one of the standard exchanges CAD file format:

• Parasolids (.x_t, xmt_txt) file

• Neutral IGES (.igs) file with trimmed surfaces

• Neutral STEP (.step) file

– Direct FEM mesh import and export:

I-DEAS, PATRAN, ANSYS, ARIES, ANVIL

– Coincident or non-coincident meshes

– Automatic 3-D mesh generation

– Export to other CAE packages

• User Friendly menu driven interface

• Platform flexibility

– Windows, Linux – 32 and 64 bits

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Material Properties

Complex phase diagrams

?

A thermodynamic database is necessary !

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Material Properties

Database

• Standard Materials Included with Procast

– 116 Metals and Alloys

– 20 Other Materials (Sand, Refractory, Foam, Air, Water)

• Thermodynamic Material Databases Available

– Alloy families: Al, Fe, Mg, Ni, Cu and Ti

– Thermo Physical properties predicted for the actual chemistry of your specific or proprietary alloy.

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Thermo-physical data

automatically set up from

the chemical composition

(Al, Cu, Fe, Ni, Ti, Mg

based)

Run the thermodynamic solver Set up the chemical composition Calculation of the solidification path

Material Properties Thermodynamic Material Databases

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Deformation (Temperature)

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~ Shell Mold can be automatically created/calculated from the part definition

Casting

Shell

Mesh

Advanced Features Automatic Shell Generation

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(Courtesy of SNECMA, France)

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Rolls Royce presentation at the

EUROPAM 2006

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Predicting Solidification Defect in

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Predicting Solidification Defect in Cast Iron Sand Gravity– Cold Shot

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Predicting Filling Defect in

Zn HPDC–Die Erosion

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Predicting Filling in

Zn HPDC–Interrupted shot

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Filling Validation

Incomplete filling

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Thixocasting validation

Sophia Antipolis, Collot Magnesium alloy (AZ91):

Filling Validation

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« Standard » Casting Simulation

However, Shrinkage Porosity and Improper Fills are

Important Defects predicted with Thermal And Fluid

Analysis, but They Aren’t the Only Defects in

Casting Processes…

THERMO PHYSICAL PROPERTIES

THERMODYNAMIC DATABASES

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“Cylinder” Model – NADCA

Benchmark HPDC process / A383 Alloy

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Guideline: Casting Modelling Phases

• Phase 2 : Filling (with extraction of thermal map at the end of cycling)

• Phase 3 : Solidification (coupled with filling)

• Phase 5 : Stress (coupled with filling and solidification)

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Heat Up Cycles

• 15 Cycles Performed to Ensure Die Soak (Cavity Region Soaked in About

9, When Starting at 200 F)

• Regions Which Stay Warm are Indicated.

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Filling

MODELING MISRUNS, OXIDES, TURBULENCES, AIR ENTRAPMENT, VENTING POSITIONING…

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Cold Fill

Ò Cold Fill As Shown In First Shot

Ò Cold Fill As Shown Even

Into Further Cycles

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Solidification

MODELLING HOT SPOTS, PREMATURE SOLIDIFICATION,…

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Ò Shrink Porosity - Not Including Gas (H 2 ) Effects.

Ò These Shrink Locations are in the Form of Dispersed Shrink Pockets (i.e., Sponge)

Micro/Macro Shrinkage Porosity

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Origin of shrinkage porosity

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Different types of Porosity

Gas microporosity

Fine pores that form at an early stage

of solidification Mainly governed by

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• Stress Concentration Determination

• Hot Tear and Cracking Identification

• Dimensional Contraction and Distortion Prediction

• Heat Resistance Caused by Gap Formation During Solidification

• Automatic Heat Transfer Coefficient Adjustment due to Gap Formation

• Thermal Fatigue of Mold

Advanced Features Coupled Thermal-Flow-Stress

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– Linear, power & kinematic hardening

• The mechanical behaviour of the mould can be

described accurately, ie:

– The stress distibution in the mould can be predicted – Thermal fatigue sensitive areas in the mould can be evidenced based on the analysis of cycling stress concentrations

• Accurate modelling of residual stresses using the

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Die Failure

Ò Highest Stress Location in the

Die Leads to a Higher Probability

of Failure

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Aluminum Die Casting

Metal arrives at gate in the following sequence:

Cavity A, Cavity B & then Cavity C.

A

B

C

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Aluminum Die Casting Short Shot shows flow imbalance between 3 cavities.

A

B

C

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Tangential gate fills along one direction (1 stream of fluid) which better allows

us to place overflows to reduce porosity.

Significant reduction in porosity (from 15%to less than 1%) (actual final gating design not shown for confidentiality).

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Skin View of Fraction Solid.

Hot spot near overflows.

Reduced overflow ingate thickness and eliminated overflow near gate.

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X-ray View of Fraction Solid.

Hot spot near overflows Reduced overflow ingate thickness and eliminated overflow near gate.

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Case Study - Steel Locking

Jaws

Casting

Shell

Mesh

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Jaws

The air cannot escape from the lower castings, because the upper ones are filling too early.

Animated image

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Jaws

This filling problem due to an inefficient

tree design leads to entrapped air

in the casting.

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Jaws

Macroporosity predicted by simulation, and by X-Ray analysis

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Jaws

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• Selected customers in investment casting, mainly in the

aerospace industry: Alstom, PCC Airfoils, PCC Structural, Howmet, Snecma, Rolls Royce, EMA, Doncasters,

Microfusione Stellite, Centro Sviluppo Materiali, Microcast, Microsteel, Precicast, AIDC, Bet Semesh, Stryker

Howmedica, MFL, GE, Pratt-Wittney, Mitsubishi,

Ishikawajima Precision Casting, Starmet, Cercast, SALUT, Harbin Donkan Engine, Shenyang Liming Aero-Engine

Group, Xi'an Aero Engine company…

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First iteration:

Initial design modification

of back shroud section (top view).

This concession allowed elimination

of five top risers (bottom view)

Case Study - Steel Sand

Casting

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Exploded view of mould assembly.

Casting

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Arrow shows shrinkage location

on front shroud

Casting

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Second iteration:

1 Chill size was increased.

2 Riser diameter was increased

Casting

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The example casting was part of a large transfer of patterns from another

foundry These patterns came fully risered and gated Although the existing

riggings yielded sound castings, it was felt that the there was opportunity for cost reductions by yield improvements and cleaning time reductions.

Original

design:

Background

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The solidification of castings without risers was done first to determine critical thermal regions and placement of risers Simulations with risers was done next For expediency reasons Fluid Flow analysis and Modeling of Feeding aids was not done as they were considered unnecessary for the type of information we were after.

Initial

iteration

(no risers):

Procedure

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This iteration shows a sound casting.

Porosity in this region was eliminated by adding a chill

Second Iteration with 5 risers

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In this example two iterations with risers were done

Number of risers was reduced from 9 to 5, pouring weight was reduced by 15 kg per casting and cut off and grinding surface was significantly reduced.

Validation with Radiography proved castings to be sound

Results

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Why Simulation is needed for

Casting ?

development

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Why ESI GROUP Casting

solution ?

• Recognized as Global Leader in Manufacturing Process Analysis

• Expert in metallurgy / Participation in many European and International projects since 1986

• Knowledge of two technologies FDM and FEM

– Reliable and accurate

– Material properties are easily accessible or computed,

• Unique capability in Investment casting, Sand Casting, HPDC due to ability in modeling the complete process:

– Shell cooling phase

– Automatic shell generator with high accuracy

– Radiation effect accurately modeled

– 3D Shot sleeve modeling with vacuum and air entrapment modeling

– Solidification with macro/micro/gas-shrinkage prediction

– Stress analysis for hot tearing, cracking, die life and part/die distortions predictions

– Advanced metallurgical modules such as CAFÉ and Microstructure modeling

– Very fast Parallel Version available

• Upgraded versions are regularly released

• Efficient worldwide customer support with local presence

• Prestigious Casting reference list WW Presence in all continents.

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Selected Casting References

– Alcoa, Alcan, Corus, Umicore, Kawasaki steel, Mitsubishi, Hydro, Novelis, Bao Steel, Böhler,…

R&D & Universities

NASA, Fraunhofer, CSM, Inasmet, ORNL, Tokyo Uni., CNRC, Centre de Haute Technologie, CTI, CTIF, Hong Kong Polytechnic University, SICHUAN UNIVERSITY, SHANXI VEHICLE

ENGINE INSTITUTE, Shanghai University, Beijing University

Foundries

PCC, Howmet, Grey Syracuse, Chrome Alloy, Gould Pumps, Citation, Amcast, Georg Fischer, Neimeng No 1 Machinery Group (Baotou) Co., Ltd, Fagor Ederlan, Enkei, Daisin, Hong Fu Jin Precision Industry (TaiYuan) Co.,Ltd., Yuanqing Aluminium wheel, ANJI FOUNDRY

WORKS, Dalian Heavy Industries Steel Casting Co.,Ltd, Guangzhou Seagull,…

Mould and die designer

MCS, Costamp, Bieffe, American Tool & Mould, Ehlert Tools, SPARTAN,

Integrated company (design/casting)

RR, EMA, SNECMA, MAN, GE, P&W, Black & Decker, KWC, Canon, Denso, SALUT, Harbin Donkan Engine, SHENYANG LIMING AERO-ENGINE Group, Xi'an Aero Engine company…

Part owner

Mazda, GM, DCX, Hyundai, Yamaha Motor, Honda, Aishin, Michelin, Chrysler, PSA, Renault,…

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Selected Casting References

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Customer Statements

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