Casting Process Design

From Start to Finish

Version 7.2.2 System Overview 6/23/09

What are the goals of Casting Process Design?

Make good (acceptable) castings Make them right the first time Make them in the most efficient way possible

What this means to the foundry tactically:

Shorter lead times Higher first-part quality Higher quality during the life of the part Less scrap Fewer customer returns Lower cost of production Lower energy consumption

What this means to the foundry strategically:

Higher profitability More customer responsiveness Better overall customer relationship Better market position Ability to fend off competition

The spectrum of foundry activity

Strategic Planning

Marketing

Production management & control Process Design

The pieces of process design

Initial Design Concepts Design Verification

Customer Specs and Data

Design Optimization

The pieces of process design

Initial Design Concepts Design Verification

Customer Specs and Data

Design Optimization

CAD Import

The pieces of process design

Initial Design Riser Design Concepts
Gating Design

Design Verification

Customer Specs and Data

Design Optimization

CAD Import

The pieces of process design

Initial Design Riser Design Concepts
Gating Design

Design Verification

Flow Analysis Solidification

Customer Specs and Data

Design Optimization

CAD Import

The pieces of process design

Initial Design Riser Design Concepts
Gating Design

Design Verification

Flow Analysis Solidification

Customer Specs and Data

Design Optimization
Optimization

CAD Import

Integrated Up-Front Design Tools

The Riser Design Wizard

Automatic sizing and location of risers

Traditional Approach
Volume Modulus = Surface Area

New Approach
Thermal Modulus calculated from solidification analysis of naked casting

The Gating Design Wizard

Automatic calculation of gating component sizes and Optimal Fill Time

Horizontal Gating

Ref: Basic Principles of Gating Design (AFS)

Vertical Gating

Ref: Modern Casting Tech Report 755 (Disamatic)

Finite Difference Solidification Modeling

CFD (Computational Fluid Dynamics) Flow Modeling

Design Verification

Design Optimization

The Basic Simulation Process

1. Select alloy and mold materials. 2. Import model shapes from CAD, or create shapes within SOLIDCast, for the casting, risers, gating, sleeves, chills, etc. 3. Mesh the model, and run the simulation. 4. Plot the results, looking at progressive solidification and prediction of shrinkage or microporosity. 5. If results are NOT satisfactory, go back to Step 1 or 2. Make changes in gating, risering, the part, or add sleeves, chills, adjust pouring temperature, etc. Then proceed to Step 3 again. 6. If results are satisfactory, you are done.

Some Basic Points SOLIDCast deals with 3D models. This means we need to be aware of the directions X, Y and Z. X and Y are considered HORIZONTAL directions. Z is considered VERTICAL. +Z is up, -Z is down. In SOLIDCast, you create projects. A project consists of models, meshes and simulations. Usually a project refers to one part number, and the various design iterations associated with that part. The steps in the project are shown on the left side of the SOLIDCast screen this is the Project Tree

Creating Basic Shapes

Blocks Solid Cylinders Hollow Cylinders Spheres

Enter Dimensions

Creating Solids of Revolution

DXF File from CAD System

Sketch Shape On-Screen

Specify Axis of Revolution and Degrees of Rotation

ADG File from AFSCad

Creating Solids of Extrusion

DXF File from CAD System

Sketch Shape On-Screen

Specify Limits of Extrusion

ADG File from AFSCad

Importing 3D Shapes from CAD

IGES, STEP, etc.

File Converter

STL File

STL File

Note: A File Converter may be a CAD system (examples: SolidWorks, SolidEdge, ProEngineer) or a viewing/conversion program such as SolidView.

Composite Models
Solid Cylinder Solid of Extrusion Solid of Revolution Solid Cylinder

STL File

Block

Solid of Revolution

Solid of Revolution

Importing Files from CAD

Required File Format: STL (Binary)

1. Start SOLIDCast 2. Select File New Model 3. On the Tool Bar, click Add a shape to the Model 4. Click the down arrow on the Shape Type field. Move to the bottom of the list of Shape Types and select STL File. 5. Click the File button. 6. Locate the STL file to load, select it and click Open 7. Click the Add Shape button. 8. Click Zoom Options on the Tool Bar and select Zoom Full

Questions Whats the difference between ASCII and binary STL files? ASCII files are text files. Binary files are encoded. How can I tell which type of file I have? If you dont know, open the file in Windows WordPad. If you can read it, its ASCII. If not, its binary. What about units Inches and mm? If your system is set to English units, SOLIDCast assumes the STL file is inches. If in metric units, SOLIDCast assumes its mm. Before selecting the file, you can specifically select inches or mm on the Add Shape window. After importing, you can check dimensions just by clicking on a couple of points. If its wrong, delete the shape and re-import.

Questions What do I do if I only have an ACSII STL file? Use the SOLIDCast STL Convert Utility Program to convert the ASCII file to binary.

Creating Basic Shapes in SOLIDCast

Cylinders, Hollow Cylinders, Spheres and Rectangular Blocks

1. On the Tool Bar, click Add a shape to the Model 2. Click the down arrow on the Shape Type field. Select the type of shape you want to create. 3. Enter the required coordinates and dimensions, and select the material type. 4. Click the Add Shape button.

Questions What if I enter the wrong dimensions, or want to change something later? You can select the shape, and then select Edit Edit Selected Shapes and change the shape parameters. What is the Priority Number? Priority numbers are important ONLY when two shapes of DIFFERENT MATERIAL overlap. The shape with the lowest Priority Number ends up in the overlap region.

Questions What is the difference between Casting Material and Riser Material? They are both casting alloy, and act exactly the same during the simulation. The main difference is that the system will display a different weight summary for each material type, so you can break the total metal weight into the casting and the rigging, to calculate yield. Also, you can specify a different HTC at the riser/mold surfaces and the casting/mold surfaces, in permanent mold simulation, when you use these different material types.

Sketching Shapes on the Screen

For making solids of extrusion or revolution.

1. First, you can (optionally) set the Snap by selecting Tools, System Parameters, Model & Sim then enter a Snap to Grid dimension. 2. On the Tool Bar, click Add a shape to the Model 3. Click the down arrow on the Shape Type field. Select the type of shape you want to create, either Revolved or Extruded. 4. Start sketching on the screen. 5. Click the check mark on the Tool Bar to close the shape. 6. Enter the shape information in the window. 7. Click Add Shape

Selecting Shapes to Edit

You can move, rotate, copy, hide, group, ungroup, edit properties or delete selected shapes.

1. On the Tool Bar, click Select Shape Mode, which is an arrow pointing to the upper left. 2. Click on any shape in the model. This shape will turn a different color (usually red) to indicate that it is selected. 3. You can select MULTIPLE SHAPES by pressing the Ctrl key when you click on the shapes.

Moving Selected Shapes

1. Once shapes are selected, then select Edit and Move Selected Shapes. 2. You can enter X, Y or Z distance to move the shape. 3. You can move the shape around using mouse clicks in an orthogonal view. 4. You can move a shape from one Pick Point on a surface to another Pick Point.

Copying Selected Shapes

1. Once shapes are selected, then select Edit and Copy Selected Shapes. 2. You can perform a Linear Copy operation, which creates one or more copies offset from the original at a given X,Y,Z offset distance or 3. You can perform a Ring Copy, which creates a series of copies, spaced evenly around an axis (for example, every 30 degrees around the Z axis would result in 11 copies of the original shape, plus the original).

Editing Selected Shape Properties

1. Once a shape is selected, then select Edit and Edit Selected Shapes. 2. You can alter any shape characteristic which appears in the window.

Hiding Selected Shapes

Sometimes it is convenient to hide one or more shapes so that you can more clearly see other shapes in the model.

1. Once shapes are selected, then select Show and Hide Selection. 2. Later, to display hidden shapes again, select Show and Show All.

Selecting Casting Alloys

1. Select Model and then Materials List from the menu. 2. Select the tab labeled Casting 3. Press the From DB button 4. Use the slider bar to move through the list. 5. Select the alloy and click OK 6. If you want to adjust Pouring Temperature, change the temperature listed as Initial Temperature.

Setting Cast Iron Properties

1. You will need to know Carbon, Silicon Phosphorus content as well as Casting Modulus and Temperature in the mold. If you dont know the Casting Modulus, use the Riser Design Wizard on the casting shape. 2. Run the Iron Property Calculation (VDG.exe) Utility Program to get % solid and amount of expansion/contraction. 3. In SOLIDCast, select Model Materials List Casting. Select an iron alloy (for example, CI DI Ferr for Ductile Iron). 4. Now select the Curves tab. 5. Click the Ductile Iron button. 6. Enter Carbon & Silicon to generate cooling curves.

7. Click on the Draw Shrk Curve button. 8. Locate the point with the % solid and expansion/contraction from the VDG program. For mold wall expansion, add 1% or 2% contraction. Click on this point and then click Done. 9. Click on Set CF Solid Pt button and move the CFS line to the % solid calculated by the VDG program. 10. To save this, go to the Casting tab, enter a unique name, and click the Add to DB button.

Selecting Mold Materials

1. Select Model and then Materials List from the menu. 2. Select the tab labeled Mold 3. On the left side are materials in the Database. On the right side are materials to be used in the model. To select materials from the Database, use the slider bar, select the material, then click Add to list. 4. You can add as many materials as you want to the list on the right. SOLIDCast will maintain this list until you change it. 5. To remove a mold material from the list, highlight it and click Remove from list.

Component Files
You can select any or all shapes within a model, and make a Component File. This can be used to create a library of standard shapes (like risers, or gating components, or chills) so you dont have to recreate these multiple times. This can also be used to make a file of a complete casting model, to transfer to another computer. Component Files contain both the geometry and the material properties of the selected shapes.

1. Select the shapes you want to make a Component File out of or select Edit Select All Shapes to get the whole model. 2. Select Model Export Selection and enter a name for the Component File. 3. This will create a file with an extension of .mdc which contains the shape(s). 4. To use this on another model, select Model Import SOLIDCast 5.x Component and then select the file. This will bring these shapes into the new model.

Planes of Symmetry
Planes of Symmetry can be used to section a SYMMETRICAL MODEL along center lines. This allows you to simulate one-half or one-quarter of the casting to save time. Later, you can use the Mirror function to mirror the data back into the portions of the model which were not simulated (this step is optional).

1. Select Model Options Planes of Symmetry 2. Select the Plane you want to activate (lower or upper X, Y or Z) 3. Enter the location (if its not 0) 4. Press the Activate button. 5. Meshing and simulation will occur only on those portions of the model which are not cut off by the Planes of Symmetry. 6. After running the simulation, if you want to mirror results, select Simulation Mirror.

Filling Simulation
SOLIDCast will perform a simple filling simulation which shows progressive temperature loss of the liquid metal during filling of the cavity. You need to specify the Fill Time (or calculate it with the Gating Design Wizard) and place Fill Material at the entry points for the liquid metal. For a more advanced fill calculation which shows temperature and velocity using true CFD fluid simulation, see the FLOWCast optional module.

Setting the Fill Time

Select Model Materials List Casting At the bottom of the screen, enter the Fill Time.

Placing Fill Material

Create a shape at the entry point of the liquid metal. Usually, this will be a cylinder at the top of the sprue. It may also be just gates attached to the casting. The shape must be large enough to be meshed with at least one row of nodes. Under Material Type, select Fill Material. Where the Fill Material touches Casting or Riser Material, the filling simulation will begin.

Cloning a Model
If you want to make a copy of a model, for the purpose of making a change and running a new simulation, use the Clone Model feature. This creates a duplicate model which you can edit and change.

1. On the Project Tree, select the model you want to clone. 2. Select File Clone Model. 3. A new model will be created.

Meshing a Model
Meshing is required before running any simulation. This breaks the model down into small cubical elements.

1. Select Model and then Create Mesh from the menu. 2. Select Node Size or Number of Nodes. 3. Select Type of Mold. 4. Select Mold Material. 5. Select Mold Thickness. 6. Select Open Top or Closed Top. 7. Click OK.

Weight Calculation
After meshing, the system will display weights of all materials.

1. Select the Mesh entry on the Project Tree. 2. From the menu, select Weights 3. A table of weights will be displayed.

Running a Simulation

1. Highlight the mesh on the Project Tree (the list on the left side of the SOLIDCast screen). 2. From the menu, select Mesh and then Start Simulation 3. To run a simulation under normal conditions, press OK.

Sand Castings

Normally, we neglect internal (material/material) HTCs when performing sand casting simulation In the Materials List, select the HT Coefficients tab. Make sure the check box labeled Use Internal HT Coefficients is blank. For the External HT Coefficient, we normally use a value of 1.5 When meshing, normally we select a Rectangular Mold.

Sand Castings, Contd

Select only as much sand thickness as you need to absorb the heat (1-2 for smaller castings, 5-6 for large castings) Use Open Top if you have open risers, use Closed Top if you have blind risers

Investment Castings

Select Investment Shell for your mold material. Set the Initial Temperature of the shell to your Preheat Temperature. To create the shell, you have two options: 1 When meshing, select Shell Mold Type 2 Use the Shell Maker utility program to create an STL file representing the shell

After meshing, be sure to use View Factor calculator to account for radiant heat exchange. Select Mesh View Factor Calculation.

Investment Castings, Contd

Why use the Shell Maker? If you have things which are external to the shell such as insulating wrap on the gating, or a bed of vermiculite in which the shell is submerged, creating a shell as part of the model makes it easier to accurately create the model. To use ShellMaker, you must have an STL file of the casting AND the gating. If parts of the model were created with SOLIDCast basic shapes, you can create an STL file using the STL from Model Utility Program.

Investment Castings, Contd

From the Tools, and select the Shell Maker Utility Program. Specify the STL file and the surface quality. This will create an STL file representing the shell. Now, in SOLIDCast select Add a Shape, select STL and select the shell file. Designate it as Shell Material, and give it a large Priority Number (like 8 or 9). Later when you mesh, select the None option for Mold Type (you already have a mold as part of the model).

Permanent Mold Castings

Make sure that Internal HT Coefficients are turned ON (in Materials List, go to the HT Coefficient tab and click Use Internal HT Coefficients) Specify an HTC for each actual (physical) interface in the model. If two materials are in contact, there should be an HTC specified for the surface between them. If the mold is rectangular in shape, you can use the Rectangular Mold option in meshing. If you want a specific mold shape, that should be created as part of the model, then select None under Mold Type in meshing.

Permanent Mold Castings, Contd

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 Castings, 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.

Permanent Mold Castings, Contd

For aluminum permanent mold castings, we recommend using the $HTRED.410 file in the SOLIDCast folder. This is a text file containing the number 0.30. This reduces the metal/mold HTC by 70% at the solidus point, per research performed by Dr. Sciama at Pechiney.

Viewing Simulation Results

This is where you plot the results of simulations to look at progressive solidification, riser feeding, shrinkage predictions, etc. This is done when the simulation is complete.

1. Double-click the simulation on the Project Tree (the list on the left side of the SOLIDCast screen). 2. The Simulation Status window will appear. Close this window. 3. To plot results, click Simulation on the menu. Various options will appear.

Plotting Options
Iso-Surface Plot: Plots one value as a 3D surface inside a transparent casting. Cut Plane Plot: Plots on a 2D plane cut through the casting CastPic Plot: Makes a 3D image of the casting, with data indicated by color mapping. CastScan Movies: Makes movie (AVI) files using multiple, multi-colored iso-surfaces within the casting.

Example Iso-Surface Plot showing Progressive Solidification

Example Cut Plane Plot

Example CastPic Plots showing Progressive Solidification

Solidification Pattern

Solidification Pattern

Casting Sectioned on YZ Centerline

Solidification Pattern

Casting Sectioned on XZ Centerline

Example CastPic Plots showing Areas of Potential Shrinkage

Casting Sectioned on YZ Centerline

Casting Sectioned on XZ Plane -7 from CL

Casting Sectioned on XZ Plane 8 from CL

Question: How do I capture these images for documenting simulation results?

Use a screen capture utility such as Pizazz, which allows you to set up the Print Screen key so that, each time you press the key, a new image file is created. These images can later be imported into Word, PowerPoint, or other documentation program.

Movie-Making Options
Iso-Surface Movie: Makes a movie of progressive values of Iso-Surface plots. Cut Plane Movie: Makes of movie of progressive values on a 2D cut plane. CastPic Movie: Makes a 3D movie image of the casting, with data indicated by color mapping. CastScan Movies: Progressive: Movie of progressive values of a data item (usually progressive solidification) Rotating: Rotating movie showing results (usually shrinkage defects)

Plot Data: Temperature

Shows the temperature in the casting (all plot types) and in the mold (only 2D plots). Temperature is shown AT THE TIME THAT THE SIMULATION STOPPED. Normally, this is at the end of full solidification.

Plot Data: Solidification Time

Shows the time, in minutes, at which each point within the casting reached FULL SOLIDIFICATION, i.e., the solidus point.

Plot Data: Critical Fraction Solid Time

Shows the time, in minutes, at which each point within the casting reached the CRITICAL FRACTION SOLID point. The CFS point is the point at which the alloy loses its ability to flow liquid feed metal. This is usually the best indication for looking at progressive solidification, to see if any isolated hot spots formed within the casting while it was solidifying.

Plot Data: Temperature Gradient

Shows the Gradient, which is a measure of how much temperature was changing during solidification over a distance in the casting. Units are C/cm. Areas of low gradient tend to be stagnant solidification, areas with high gradient are usually solidifying pretty well directionally.

Plot Data: Cooling Rate

Measures how quickly a casting was cooling during solidification. Normally, rapid cooling is associated with better materials properties: Smaller grain size, more dispersed and dissolved alloying elements, higher strength. Units are C/Minute

Plot Data: Material Density

A measure of Macroporosity (macro shrinkage) in the casting. Value ranges from 0 to 1. Lower values are worse. Usually, the Critical Value is around 0.99 to 0.995 (values below this indicate visible shrinkage).

Plot Data: Niyama Criterion

A measure of Directional Solidification in the casting. Low values are bad, high values are good. A value of 0 means lack of directional solidification (usually a thermal center in the casting). Can be used to identify potential for centerline shrinkage.

Plot Data: FCC Criterion

A measure of the potential for Dispersed Microshrinkage (Microporosity) in the casting, or Secondary Shrinkage in iron castings. The Critical Value is usually around 40% of the total range. For example, if the range is 0 to 8, the Critical Value would be around 3.2. Lower values are less severe, high values are more severe.

Typical Plot Sequence for Simulations:

Look at various values of Critical Fraction Solid to see the sequence of solidification, and to look for isolated hot spots. Look at Material Density in the range of 0.990.995 to highlight areas of potential shrinkage. Look at FCC Criterion at 40% of range, to look for tendencies for microshrinkage or secondary shrinkage. Look at Niyama for possibility of centerline shrink.

ISO-SURFACE PLOTS are fastest and easiest!

Basics of Riser Design

Chvorinovs Rule:

t = B (V/A)2
t = Time to complete solidification B = Mold Constant V = Volume of a section of the casting A = Surface area of the same section of the casting

Basics of Riser Design

(V/A) is referred to as the Casting Modulus

Casting sections with low modulus solidify first. Casting sections with high modulus solidify last.

Basics of Riser Design

Shapes with high Modulus

Shapes with low Modulus

Basics of Riser Design

Directional Solidification

Increasing Modulus

Lowest Modulus

Highest Modulus

Using the Riser Design Wizard

1. Import a 3D model of the casting. 2. Select alloy and mold materials. 3. You MAY elect to place gates to take filling into account. 4. Run a simulation of the casting with no risers. 5. Double-click the simulation on the Project Tree (the list on the left side of the SOLIDCast screen). 6. The Simulation Status window will appear. Close this window. 7. Select the Riser Design Wizard from the menu.

An example of using the Riser Design Wizard

Using SOLIDCast, the typical approach to process design for a new casting is to allow the system to analyze a casting without risers and determine the best suggested design for risering. This is done with the SOLIDCast Riser Design Wizard.

Here is an example casting model, imported as a 3D shape from a CAD system.

Using the Wizard approach, we first perform a simulation of just the casting, filled through the gates but with no risers. The results of this simulation appear as follows:

Casting simulated with no risers

Now, we run the Riser Design Wizard, which takes the results of this simulation and suggests what risers are required.

We start by telling SOLIDCast to Design Risers

SOLIDCast has determined that 3 risers are required for this casting

SOLIDCast then shows us each of the feeding areas within this casting that have been identified.

Feeding Area 1

Feeding Area 2

Feeding Area 3

Next, SOLIDCast shows us where the optimum point of attachment for a riser would be in each of these three areas. This point is the spot in each area which has the highest Section Modulus.

Attachment Point for Riser 1 Attachment Point for Riser 2

Attachment Point for Riser 3

Finally, SOLIDCast suggests an appropriate size for each riser. This calculation is based on both Section Modulus (volume/surface area ratios) and required feed metal volume for each feed area.

Here is the suggested design for Riser 1 (without a sleeve)

And for Riser 2 (with a sleeve).

And finally, for Riser 3 (also with a sleeve).

Now, we add the suggested risers at the suggested locations to the SOLIDCast model.

Riser 2 (Ins. sleeve) Riser 3 (Ins. sleeve)

Riser 1 (No sleeve)

Basics of Gating Design

Objects in Free Fall

Acceleration of Gravity: g = 32.2 ft/sec2

V =

2gH

Basics of Gating Design

Liquid Metal in Free Fall

V =

2gH

Basics of Gating Design

Flow of Liquid Metal Through a Channel (Runner or Gate)

Flow Rate (in3/sec) = Velocity (in/sec) X Area (in2) Or Area = Flow Rate Velocity

Using the Gating Design Wizard

1. Run a simulation of the casting with no risers. 2. Double-click the simulation on the Project Tree (the list on the left side of the SOLIDCast screen). 3. The Simulation Status window will appear. Close this window. 4. Select the Gating Design Wizard from the menu.

The SOLIDCast System also includes a program called the Gating Design Wizard. This function analyzes the casting and alloy selected, calculates weight of poured metal, suggests an Optimum Fill Time for the casting, and then details sizes of sprues, runners and gates for best filling.

Lets see how this would work

First, we specify the class of alloy we're pouring (in this case, Aluminum Alloy) Next, the system calculates Pour Weight for us. Then, we describe the Critical (thinnest) section thickness. And finally, the system tells us the Optimum Fill Time for this casting (in this case, about 20 sec.)

The next step is to describe the sprue height and the location of the gating relative to the casting.

This allows the system to calculate an Effective Sprue Height to use for gating calculations.

Now, since we have two sprues, well divide the weight in half for each sprue and calculate the associated gating (35 lbs of metal will go down each sprue).

The gating ratio (Sprue:Runner:Gate) can be specified here. The ratio 1:4:4 is recommended by AFS for most nonpressurized systems.

Dimensions at top and bottom of the first sprue are given here.

Dimensions of the runner prior to the first gate, and dimensions of that gate, are given here.

Dimensions of the next section of the runner, and the second gate, are given here. This ensures adequate and even flow to both gates.

Now we consider the second sprue, runner and gate. Dimensions of the second sprue are given here.

And dimensions of the runner and single gate are given here.

Now, within a few minutes, we have calculated all of the dimensional data that we need in order to design the gating for this casting. Lets see how this would look on the final model

Gate: 1 x .642

Sprue: .77 x .77 Top, .553 x .553 Bottom

Runner: 1.5 x .428 Gate: 1 x .611

Runner: 1.5 x .815

Runner: 1.5 x .815 Gate: 1.5 x .815

Sprue: .77 x .77 Top, .553 x .553 Bottom

Now, with the process design as provided by the SOLIDCast Riser Design Wizard and the SOLIDCast Gating Design Wizard, we can run a simulation of the casting process using SOLIDCast to verify the results of the design.

Here is a plot of the sequential areas of solidification in the casting.

We can section this to view internal areas:

In this view the predicted internal porosity is shown:

The casting has been produced with no internal porosity in this section.

And now we examine the casting with a horizontal section showing progression of solidification:

And the same view showing predicted internal porosity:

Again, there is no visible porosity in this section.

With an X-Ray view we can see all internal areas of the casting at one time, to determine that there is no porosity anywhere within the casting.

The result: By using the SOLIDCast process design tools, we have very easily and quickly produced a design for production of this casting which will result in a very sound cast part.

Another Example of using the Riser Design and Gating Design Wizards:
A quick look at a new casting.

Casting Design

File: type_c_interim_ref.stl Dated: 04/15/03

Analysis of Feed Areas & Required Risering

The Riser Design Wizard identified (6) distinct feeding areas within the casting. In the following images, each area is identified and the calculated riser size is shown. Calculations are based on a sand riser (no sleeves).

Area 1: Requires 12 x 20 Riser

Area 2: Requires 16 x 20 Riser

Area 3: Requires 14 x 20 Riser

Area 4: Requires 18 x 24 Riser

Area 5: Requires 16 x 20 Riser

Area 6: Requires 14 x 20 Riser

Calculation of Optimal Fill Time

Based on an estimate of total poured weight, and Critical Section Thickness (thinnest section of the casting), the Gating Design Wizard estimates an optimal fill time for pouring the casting.

The Gating Design Wizard estimates a Fill Time of 78 seconds for this casting

Once number of gates and sprue and runner locations are established, the Gating Design Wizard can be used to calculate proper size for sprues, runners and gates for correct filling of the casting cavity.

Flow Simulation for Mold Filling

1. Models are generally built the same way you would build them for SOLIDCast simulation. 2. Normally we include the entire gating system when simulating with FLOWCast. 3. Calculate Optimal Fill Time using the SOLIDCast Gating Design Wizard. 4. For bottom-pour ladles, you can calculate a variable flow rate using the Ladle Calculation Utility, too.

Using FLOWCast
FLOWCast assumes that metal flows in perpendicular to Fill Material surfaces. Therefore, you should avoid plunging Fill Material into the top of a sprue:

Right

Wrong

Using FLOWCast
There are two ways to start FLOWCast. Method 1: Use Mesh Start FLOWCast

This loads FLOWCast. You then select settings and start the flow simulation manually.

This is the FLOWCast main screen. You can adjust the display from this screen. To set the steps for saving data, click the Filling tab.

This allows you to set the increment for saving ALL data (temperature and velocity) and also just temperature data, which creates a smaller output file.

Here weve set the increment for saving temperature data to 1%. This will allow us to create a video file later on using 100 frames or pictures.

FLOWCast allows you to select either a FULL CFD solution or a Quick solution. When the hourglass button is depressed, this indicates youve selected the Quick solution.

To start the flow simulation, click the double arrow.

The Status tab shows data sets saved for FULL data, and is also where you go to create animation files of temperature, velocity and pressure after the simulation is complete.

The Anim tab shows sets of saved temperature data, and is also where you go to create movies showing temperature when the simulation is complete.

The Pathlines tab allows you to turn on or off the tracks of virtual particles which are released into the incoming metal at every 10% increment of fill.

Using FLOWCast
Q: How do I use results of a FLOWCast simulation as the start of a SOLIDCast simulation? If youve run FLOWCast using the Mesh Start FLOWCast option, just start a simulation using Mesh Start Simulation and pick SOLIDCast as the Fill Algorithm:

Using FLOWCast
If you want to run FLOWCast and then SOLIDCast automatically, use Method 2:
First, select Mesh Start Simulation Then specify the FLOWCast Algorithm (Full or Quick) you want to use

Ways to Visualize Flow Patterns with FLOWCast

1. Velocity Vectors 2. Trace Particle Paths

Velocity Vectors are plotted on sectional planes cut through the model. To set up plotting of Velocity Vectors, we first need to select Velocity as the item to plot.

Next we select a view or rotate the model to the desired view.

We can turn off Perspective

 to get an Orthogonal view.

From the Settings menu we can select the color for the Velocity Vectors

 the thickness of the vectors

 and the size of the vector heads.

To turn on vector plotting, we select a Cutting Plane (in this case the X-Z Plane) and ask the system to Display Veloc Vectors on Plane.

Velocity Vectors show the direction of flow of metal at every point on the cutting plane

 showing flow streams, vortices and areas of high and low velocity.

Particle Tracks Particle tracks shows the path of simulated particles released into the incoming stream at specific intervals.

Particle tracks are turned on by selecting the Pathlines tab. Color, thickness and number of tracks can be controlled with the Settings menu.

This shows paths of particles released at the start of filling.

At 20% full

At 50% full

And at 80% full. Particle tracks can also be included in movie (AVI) files.

A Third Example of Using the Riser Design and Gating Design Wizards:
Designing for multi-cavity production

Using SOLIDCast and FLOWCast software, we will develop a design for the rigging and production of this 356 aluminum alloy casting. The first step involves consideration of the casting geometry, without gates or risers.

Casting model as furnished by the foundry.

Casting model as furnished by the foundry.

Using the Riser Design Wizard in SOLIDCast as a starting point, we analyze this shape to determine the Modulus* of the casting. Modulus is a predictor of the order of solidification of various parts of the casting, and can be used to indicate the best attachment points for gates and risers, as well as appropriate sizes for risers.
*Note: The traditional Modulus used in casting design is defined as the ratio of Volume:Surface Area. SOLIDCast uses a Thermal Modulus which is more accurate than traditional V/SA analysis.

Plot of Modulus values in this casting.

Plot of Modulus values in this casting.

Point of maximum Modulus. This is the last point to freeze, and the best place to attach a riser.

The Riser Design Wizard can analyze the patterns of Modulus values within a casting and make recommendations as to how many risers are required, where they should be placed, and what size they should be.

Heres the Riser Design Wizards starting screen.

By analyzing patterns within the casting, the Wizard tells us that three risers would be the optimal design.

Next, by using an X-ray view of the casting, we can see where these highmodulus areas are in the casting. In theory, each of these areas should be fed by its own riser.

Main feeding area Secondary feeding areas

The next series of views shows the location suggested by SOLIDCast as the best attachment point for the main riser, considering the point of highest modulus within the casting.

Now, the Riser Design Wizard is able to recommend riser sizes for each of these areas. Riser size is determined by consideration of Modulus (the Modulus of the riser should be greater than the Modulus of the casting) and volume (the volume of the riser must be sufficient to provide feed metal to compensate for the contraction of the alloy during liquid cooling and solidification).

Here, the required riser size is given as 2 diameter X 5 high. The volume requirement controls. This is for the main riser for one casting.

Assuming that we might feed two castings with a common riser, we can adjust riser dimensions to provide enough feed metal for two castings.

Doing this, required riser size to feed (2) castings is 2.5 diameter X 6 high.

Now we can ask the system to size the smaller, secondary risers, as follows:

Riser 2 is given as 1.5 diameter X 3 high.

And Riser 3 requires the same dimensions, 1.5 diameter X 3 high.

Next, the Gating Design Wizard can give us a suggested Optimal Fill Time and sizes for sprue, runners and gates.

Calculating a Pour Weight for (4) castings per mold, and taking into account the Critical Wall Thickness of 0.217 in the casting, the Gating Design Wizard suggests an Optimal Fill Time of 8.7 seconds.

Here we specify the gating arrangement and a gating ratio of 1:2:2

The Wizard tells us we should have a sprue that is .897 diameter (weve assumed a round straight sprue here).

And the runner size should be .632 square inches.

Using this information, we can create an initial gating and riser design for production of this casting in a 4-on mold.

Initial Suggested Design for Gates and Risers

What happened to the secondary risers 1 and 2? In our initial design, we will test to see if the temperature distribution due to filling through the main riser will be enough to overcome the need for secondary risers, by encouraging directional solidification into the large riser. If not, well add them later or we could try chilling those areas instead.

The next step is to run a simulation of this casting, using the initial design. This will involve using FLOWCast to model the flow of the liquid into the casting, and SOLIDCast to model solidification and shrinkage formation. This will allow us to evaluate this design and determine whether any further modifications are necessary.

FLOWCast is a flow simulation module which models the filling of the gating and mold cavity. FLOWCast models progressive temperature and velocity of the liquid metal.

The following series shows progressive temperature of the liquid metal during filling.

FLOWCast can also show flow pathlines, or particle trace lines. This helps to visualize the flow of the metal and determine whether any excessive vortexing or turbulence may be occurring. This can also be used to predict the likely end location of foreign particles (oxides or dirt) entrained in the metal stream.

Flow Pathlines

FLOWCast can also show velocity of the liquid metal at any point in the liquid.

FLOWCast can also show pressure of the liquid metal at any point in the liquid.

FLOWCast is used to visualize how the gating will function, and how the mold will fill. Flow-related defects such as misruns or cold shuts can be identified. It also provides the most realistic temperature distribution in the casting and mold for a subsequent solidification analysis. In this case, the flow sequence looks good. Now lets progress on to analysis of the solidification of the casting.

SOLIDCast is used to predict the cooling and solidification of the casting after filling, as well as formation of any shrinkage (macroporosity or microporosity).

Here we see the predicted final temperature distribution in the casting, at the end of solidification.

This shows a good temperature gradient from the far side of the casting back into the risers.

This image shows the pattern of solidification in the castings.

This shows a good pattern of directional solidification out of the castings and into the risers.

Prediction of macroporosity (shrinkage) in the castings.

X-Ray View

Prediction of areas of microporosity (dispersed micro-shrinkage) in the castings.

X-Ray View

Conclusion By using the gating and risers as suggested by the Gating and Riser Design Wizards, we were able to design the process for this casting very rapidly. By using FLOWCast and SOLIDCast, we were able to verify through simulation that this design should produce a sound casting.

Casting Analysis

737305 INSERT

9-April-2004

Step 1: Casting Model as Imported from CAD File

Step 2: Analysis of Thermal Modulus

Step 3: X-Ray View of Thermal Analysis For Feeder Locations

As identified automatically by the SOLIDCast Riser Design Wizard.

Feeder Location 1

Feeder Location 3 Feeder Location 4

Feeder Location 2

Step 4: Calculation of Required Feeder Size at Each Location

(In this calculation, we have assumed no sleeves.) This approach considers Modulus and Volume Requirement for each Feeder.

Step 5: Calculation of Gating Components: Sprue, Runners and Gates

Calculation of Optimal Fill Time

Specification of Gating Parameters

Calculation of Sprue Sizes

Calculation of Runner and Gate Sizes

Step 6: Development of Initial Rigging Design for Casting Production

Design #1

Filling Simulation: 10% Full

Filling Simulation: 80% Full

Filling Simulation: 100% Full

Temperature Distribution at End of Solidification

Progressive Solidification

X-Ray View of Shrinkage (Macroporosity) Prediction

Small Area of Predicted Shrinkage

Step 6: Design Iteration #2

Design #2

Two smaller top feeders

Filling Simulation: 10% Full

Filling Simulation: 80% Full

Filling Simulation: 100% Full

Temperature Distribution at End of Solidification

Progressive Solidification

X-Ray View of Shrinkage (Macroporosity) Prediction

No Predicted Shrinkage in Casting

Timing Data CFD Flow Simulation: 111 Minutes Solidification Simulation: 13 Minutes

An Example in Cast Iron

The Iron Property Calculator With Riser Design

First, the STL file is loaded.

This is what the shape looks like.

I select a 4 CE gray iron as the Casting Alloy. I have adjusted the pour temperature to about 70 degrees below the 2550F temperature you gave me, because we are initially going to simulate the iron already in the mold and a 70F temperature drop is a typical estimate for the loss from filling.

I select silica sand as mold material.

And make sure that Internal HT Coefficients are not turned on, and the External HT Coefficient is set to about 1.5.

Now we mesh the model with a relatively coarse mesh 500,000 Nodes with 3 of sand all around.

And we start a simulation running.

The simulation should run fairly quickly.

When the simulation is done, we double-click on Simulation on the Project Tree, which displays the Simulation Status window. We close this window.

Then we select Simulation Riser Design Wizard. All we are doing at this point is calculating the modulus of the casting.

In the Riser Design Wizard, we select Calculate and Display Casting Modulus and press Next.

Then we select Plot Iso-Surface and press Next.

On this window we can see the maximum value of modulus, which is 1.215. This is the casting modulus. Thats all we need for the moment, so we cancel this plot and close the Riser Design Wizard.

We also need the casting weight, so we select Mesh and Weights from the menu.

And we see that the weight of the casting is about 812 pounds.

Next we go to the Tools menu and select Iron Property Calculator.

Here I have assumed a carbon content of 3.4%, silicon 1.8% and P of 0.02%. We fill in the casting modulus as 1.215 (calculated previously) and for Temperature in the Mold we enter 2480. Pressing the Calculate button, we see that the Shrinkage Time is 41.88% and the amount of contraction is 2.19%. Next, we press the Riser Design button.

This brings up the new Iron Casting Riser Design window. We fill in the weight of 812 lbs, set the amount of mold dilation to 1% (for green sand), assume a side sand riser and set the H:D ratio to 1.5.

Now, pressing Calculate, we see the required sand riser size is about 8.4D x 12.6H. Also note that the Neck Modulus is .786.

Here are the dimensions if we have an Insulating Sleeve.

And for an Exothermic Sleeve.

Closing the Iron Casting Riser Design window, we now go back to the Simulation Riser Design Wizard function. Now that we know the neck modulus, we want to see if there is a single feeding area or multiple feeding areas in this casting, using the neck modulus as a guide.

In the Riser Design Wizard, again we select Calculate and Display Casting Modulus and press Next.

Then we select Plot Iso-Surface and press Next.

Now on the plot parameters, we enter the neck modulus which is 0.786 into the Plot This Value field. Then we press OK to plot this value.

This plot shows that there is a SINGLE FEEDING ZONE in this casting, based on the neck modulus. This means we should use a single riser on this casting.

This is what a sand riser might look like, based on the dimensions as calculated with the Iron Casting Riser Design program.

Now we want to know what size sprue and gate to design for this casting. We select Simulation Gating Design Wizard, select Horizontal Gating, enter an estimated pouring weight of 1200 lbs., section thickness of 3.2 inches and press Calc. Fill Time. This gives us a calculated Optimal Fill Time of 53 seconds.

Here we make some assumptions about sprue height and specify a gating ratio of 4:8:3 (pressurized).

The program tells us that the top sprue diameter should be about 3.5 and the bottom diameter about 2.1.

Now we design a gate. The best configuration is to gate into the riser, and to keep a 1:5 ratio of H:W on the gate so that the gate freezes quickly enough. The program calculates a gate size of 0.5 x 5.3 for this condition.

Adding this simple gating system to the model, we end up with a system that looks like this.

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?

The highest quality casting at the

lowest cost. The most efficient way to produce a casting.

The current process

Initial Design Foundry Engineer

Process Simulation System

Revised Design

Simulation Results Not Acceptable? Decide What to Change Foundry Engineer

Acceptable? Done

A new paradigm

Initial Design Foundry Engineer

Process Simulation System

Revised Design

Simulation Results Not Acceptable? Optimization Engine Decide What to Change

Acceptable? Done

The Layered System Approach

Optimizing Engine

Casting Process Simulator

Computer Operating System and Hardware

What is Optimization?
Optimization is a mathematical method for finding the best solution to a given problem. Automates the search for a design solution Frees the engineers time Provides a more thorough and repeatable design process.

Steps Required for Optimization

1) Develop an Initial Design. 2) Define three types of elements: Design Variables Constraints An Objective Function 3) Launch the Optimization

Design Variables
These are elements that are allowed to vary when the computer is searching for an optimum process design. Examples: Height and diameter of a feeder (riser) Size of a feature on the casting Pouring temperature Shell preheat temperature

One Type of Design Variable Geometric Feature Size

Another Type of Design Variable: Initial Temperature

Constraints
A constraint is some aspect of a design that determines whether that design is acceptable or not. Typical Constraints: Macroporosity Level Microporosity Level Yield Percentage Minimum Cooling Rate Minimum Thermal Gradient

The Objective Function

The Objective Function is the single result which you are trying to either maximize or minimize. Typical Objective Functions: Maximize Yield Percentage Minimize Macroporosity Level Minimize Microporosity Level Maximize Cooling Rate Maximize Directional Solidification

The Optimization Process

The Optimization Engine varies each Design Variable within the Design Space to create a series of process models. Each design is evaluated as to whether it violates any Constraint. Each design is then evaluated to determine if the Objective Function has been achieved, through the use of convergence criteria.

How OPTICast Works

Modify the 3D Simulation Model Decide on new values for Design Variables Yes/No Were Constraints violated?

Run a Simulation with

Was an optimum value of the Objective Function achieved?

Examine Results

No/Yes

DONE

The Optimization Engine evaluates Response Surfaces.

Requirements of the Modeling System for Application of Optimization

Must be able to automatically modify geometry Must be able to handle shape interference as shapes are modified Must be able to automatically remesh each design Must be able to process multiple simulations as quickly as possible

Optimization allows us to take an initial process design and, from that design, find the OPTIMUM design which will result in maximum part quality and minimum part cost.

Example: Automotive casting Current Design

Current Riser Dimensions: 92 mm Dia. at P/L 175 mm Overall Height

Simulation of current riser shows adequate size and mass to feed the casting properly.

Sectional view showing simulation of current riser feeding

X-ray view showing simulation of current riser feeding

Question: Can the weight of the riser be reduced, and yet still provide adequate feeding to the casting? We can answer this question using mathematical optimization.

The OPTICast system combines the SOLIDCast casting simulation package from Finite Solutions, Inc. with HyperOpt Optimization from Altair Engineering.

In order to perform optimization on this riser design, we need to define three parameters: Design Variables Constraints Objective Function

Design Variables are any aspects of the design that we will allow the optimizer to vary during the optimization run.

Here we have selected the riser as a Design Variable. Its Height and Diameter will be allowed to vary independently.

A Constraint is an output which determines whether a design is acceptable. Here we set Casting Porosity as a constraint. Porosity is measured by considering the minimum local material density in the casting. The constraint value is set to 1.0, which indicates no casting porosity allowed.

The Objective Function is a simulation output which measures the end result we are trying to achieve.

For purposes of this optimization, we define a yield number such that Casting Weight Yield = Casting + Riser Weight The Objective Function is the maximization of this number, which results in minimum riser weight.

The Optimization Process

The Optimization Engine varies each Design Variable within the Design Space to create a series of process models. Each design is evaluated as to whether it violates any Constraint. Each design is then evaluated to determine if the Objective Function has been achieved, through the use of convergence criteria.

How OPTICast Works

Modify the 3D Simulation Model Decide on new values for Design Variables Yes/No Were Constraints violated?

Run a Simulation with

Was an optimum value of the Objective Function achieved?

Examine Results

No/Yes

DONE

Optimization Results The riser design optimization was complete after 26 simulations. These were run completely automatically. Total processing time was 2 hr. 56 min. on a 1.0 GHz PC.

This chart shows the progressive value of the Yield function over 26 simulations. Its value started at 0.60 and ended at 0.72.

This chart shows simulated porosity in the casting. A value of 1.0 represents a completely sound casting. Final value of 0.9995 is within allowable limits.

A plot of the vertical scale of the riser. The final riser design is 13.1% taller than the current riser.

A plot of the horizontal scale (diameter) of the riser. The final riser design is smaller (72%) in diameter than the current riser.

Comparison of current riser vs. optimized riser design

92 mm Dia. X 175 mm Height.

66 mm Dia. X 198 mm Height.

Simulation of the optimized riser design shows adequate size and mass to feed the casting properly.

Sectional view showing simulation of optimized riser feeding

X-ray view showing simulation of optimized riser feeding

Optimized riser shown with gating

Weight Reduction

Current Riser Weight: Optimized Riser Weight: Weight Reduction/Riser:

16.03 lbs. 9.39 lbs. 6.64 lbs.

Weight Reduction/Mold (8-on): 53.1 lbs.

Conclusion of Optimization: Pour weight per mold can be reduced by

53.1 pounds through redesign of the riser by optimization At current production volumes, this results in a saving of more than $US 100,000 per year (1800 tons of metal saved annually) Annual Energy Savings: 1,980,000 KWH

Process Design Optimization for:

Stainless Steel Investment Casting

Pour Temperature: 2925F Shell Preheat: 1800F Shell Thickness: 0.5 Alloy: CF8M

In this case, we start with Design Iteration #7, which produced a shrink-free casting.

Wedge shapes, approx. 1.5 wide

This design used two small wedge shapes under the gates to help feed metal into the heavy section of the casting.

Heres the gate design that will be optimized by using OPTICast.

The first step is to select Design Variables. These are features of the gating that are allowed to vary in size.

Here weve selected the horizontal feeder bar as Design Variable #1.

The pour cup is selected as Design Variable #2.

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.

The gates height is held constant, but its width is allowed to vary.

The other gate is linked to the first gate, which means that the two gates will always be the same shape.

Now we need to apply a Constraint. This is an OUTPUT VALUE from each simulation which determines whether the results are acceptable or not. In this case, our constraint is that the casting must be free of shrinkage. Any design which results in shrinkage in the casting will be discarded.

We measure shrinkage as Material Density. A value of 1 means a perfectly sound casting, so we set the Constraint Value to 1.

Finally, we select an Objective Function. This is an OUTPUT VALUE that we are trying to either maximize of minimize. In this case, our objective function will be to Maximize the Yield. This means that the maximum yield (i.e., the minimum amount of poured metal weight) which produces a shrink-free casting will be found.

This is done just by selecting Yield Maximization from a list of Objective Functions.

At this point, we start the optimization running. This is a TOTALLY AUTOMATIC process. OPTICast will run a series of simulations, varying the gate design until the yield is maximized and the casting is shrink-free. This process can be illustrated as follows:

The Optimization Process

Modify the 3D Computer Model Decide on new values for Design Variables Yes/No Were Constraints violated?

Run a Simulation

Was an optimum value of the Objective Function achieved?

Extract Results

No/Yes

DONE

In effect, the computer is redesigning this gating system ON ITS OWN, using the rules and guidelines that we set up.

Now lets look at the Results

Here is the Yield for each of 50 simulation runs.

The yield increased from 38% to 53%.

This chart shows casting soundness for each of 50 simulation runs.

A value of 1.0 means a sound casting (no shrink).

This shows the horizontal scale factor for the feeder.

The optimized feeder is 82% of its original size (horizontally).

This chart shows the vertical scale factor for the feeder.

The optimized feeder is 83% of its original size (vertically).

This shows the horizontal scale factor for the pour cup.

The optimized pour cup is 42% of its original size (horizontally).

And, finally,this chart shows the horizontal scale factor for the gates.

The optimized gates are 120% of their original size (horizontally).

So, how does the optimized design compare with the original gating design?

Solidification Pattern

Hot Spots

No Hot Spots

Original Gating

Optimized Gating

Shrinkage Prediction

Shrinkage in Casting

No Shrinkage in Casting

Original Gating

Optimized Gating

Original Gating

Optimized Gating

123 Lb. Pour Weight

88.3 Lb. Pour Weight

Final Results 1. Pour weight reduced 34.7 Lbs. per casting 2. Shrinkage eliminated from casting 3. Annual savings: $17,000 4. Energy savings: 7,000 KWH/yr

Utilities Menu

The Utilities Menu gives access to a wide variety of functions.

Convert ASCII STL to Binary

Allows you to convert an ASCII STL file to a Binary STL file so that it can be loaded into SOLIDCast as a model shape.

Create Shell Around STL Shape

This program accepts an STL file as input, and creates a new STL file as output which represents a shell of a constant thickness around the first STL file. This shell shape can then be brought into the SOLIDCast model as a model shape.

Custom Formula

Allows you to create a customized formula for calculation and plotting from SOLIDCast results. For example, in aluminum alloys a formula for Dendrite Arm Spacing (DAS) in microns is: DAS = 35 (ts-tl) 0.333 and in Steel a formula is: DAS = 100 (ts-tl) 0.41 Both of these formulae can be entered using Custom Formula, and plotted using Custom-High.

Data Capture (Temperature)

Allows you to capture time/temperature data from an unlimited number of points within a model.

Early Fill Tilt Pour

This utility allows most of the metal in a tilt pour FLOWCast simulation to enter the mold at a given percent of tilt. For example, if the mold tilts through 90 degrees during filling, and the user specifies 50% as the completion point, then most of the liquid metal will have entered the mold during the first 45 degrees of tilting.

Filter Shape

This utility helps you to create an STL file consisting of a rectangular block with cylindrical holes. This object, when added to a model and given ceramic thermal properties, can be used to simulate a filter.

HTC Calculator

This utility helps to calculate the appropriate Heat Transfer Coefficients to use for various situations. Calculations are included for:

Air and water cooling channels Natural and forced convection Radiation Mold coatings

Iron Property Calculator

Allows you to calculate % contraction/expansion and CFS point for cast iron, based on the German Iron Society VDG Nomograms and the charts developed by Karsay. This utility also performs risering calculations for cast irons, as demonstrated in the following slides.

Design of risers for Grey Iron and Ductile Iron castings involves one primary consideration above all else:

Control of Expansion Pressure

This means allowing riser necks to remain open long enough to feed liquid shrinkage, but ensuring that they freeze in time to pressurize the casting during expansion and avoid formation of shrinkage porosity.

The solidification of iron castings (ductile, or nodular, iron and gray iron) is unique among cast metals, due to the precipitation of graphite as the iron solidifies. The graphite takes various forms depending on the type of iron. For example, in ductile iron (nodular iron), the graphite is primarily spheroidal, which gives the iron its characteristic ductility since the spheroids tend to reduce localized stresses under load.

While in gray iron, the graphite tends to be in the shape of flakes, which results in gray irons great compressive stress but relatively low tensile stress.

And in compacted graphite iron, the structure and properties tend to be somewhat intermediate.

The precipitation of graphite during solidification causes some expansion to occur, because the graphite is much less dense than the surrounding iron. Therefore, we have several forces at work. The liquid iron tends to contract as do almost all liquids when cooled. During solidification, the austenitic iron also contracts as do most metals upon solidification. However, the precipitating graphite causes an expansion pressure which can be used to our advantage if the feeding system is properly designed.

No matter which type of cast iron we are pouring, the secret of good design is to provide a feeding system to compensate for the liquid shrinkage and then allow the expansion (due to carbon precipitation) to provide enough pressure to produce a sound casting. There are some differences in expansion pressure between ductile iron and grey iron as shown in the following chart:

Regardless of the type of iron casting we are designing, there are a set of basic procedures that can be followed which will help us to ensure high-quality, sound iron castings, using the SOLIDCast Simulation System. These procedures will help to minimize the number of sample castings required, reduce lead times to get into production, and result in consistent-quality castings which will make our customers happy and our foundry more profitable.

Step 1 To begin analyzing a casting in SOLIDCast for the purpose of riser design, we initially run a simulation of just the casting, surrounded by mold material, without gates or risers.

Step 2 We then run the SOLIDCast Riser Design Wizard and select "Calculate and Display Casting Modulus" to find out the maximum modulus of the casting.

Step 3 We next run the SOLIDCast Cast Iron Property Calculator program to calculate the Shrinkage Time (ST) and net Percent Expansion (+) or Contraction (-) of the iron based on chemistry, modulus and temperature in the mold. This is based on the VDG Nomograms and Karsay charts for iron properties.

Step 4 This gives us the net expansion of the iron considering only the metal, without taking into account the dilation of the mold. For actual feeding requirement, we must estimate mold dilation which might vary from less than 0.5% for chemically-bonded molds to more than 2% for loose green sand molds.

Step 5 Rule: Recommended practice would be to use a "hot" riser, i.e., to gate into the riser if using a side riser so that the amount of heat in the riser, and its ability to provide feed metal, is maximized. For top risers, since it is difficult to gate into these, we would typically recommend a sleeve (either exothermic or insulating) to retain the heat.

Step 6 The proportion of liquid metal that can be supplied by a riser can be estimated by knowing its condition. For example, a hot side riser can typically provide about 20% of its metal for feeding, while a typical cold riser might provide around 14% of its metal. A sleeved riser can provide anywhere from 33% to 35% depending on its condition. Exothermic mini-risers have been known to provide up to 70% of their metal for feeding.

Step 7 The formula relating the available volume of metal in a riser to the volume of the casting can be expressed as: Vf = ______ Vc * S x
(Where Vf = Riser Volume, Vc = Casting Volume, S = Feeding Requirement (including Mold Dilation), and x = Proportion of Liquid Metal Removed from Riser)

and from this the diameter of the riser can be calculated if an assumption of riser Height:Diameter is made.

Step 8
The riser neck should be sized so that its modulus guarantees that it will freeze at the point that the liquid shrinkage is done and any subsequent expansion will be controlled and contained within the casting to prevent shrinkage porosity formation. This can be accomplished by using the following formula: Mn = ST/100 * Mc Where Mn = Modulus of the Neck, ST = Shrinkage Time, and Mc = Modulus of the Casting.

Step 9
Also, in order for the riser to provide sufficient liquid melt during the shrinkage period, its modulus should be 20% greater than the neck modulus, which means the riser size should satisfy the equation: Mr = 1.2 Mn or Mr = 1.2 ST/100 Mc

So that if the riser is sized to satisfy the liquid feeding requirement but it does not satisfy this modulus requirement, its size must be increased to satisfy this modulus requirement.

Step 10 If the riser is close enough to the casting so that mold heatup between the casting and riser can be taken into account, the required modulus of the neck can be reduced by multiplying by a factor of 0.6. Rule: In order to be considered a short neck, the distance between the casting and the riser should be less than the minimum dimension of the riser neck.

Riser Neck

Step 11 How many risers are required for a casting? Rule: Only one riser should be used for each feed zone within a casting. Feed zones can be visualized by plotting the neck modulus, also called the Transfer Modulus. If more than one riser is used for a single feeding zone, in almost all cases only one of the risers will pipe and the other riser(s) will not pipe but will create a thermal hot spot underneath at which some shrinkage porosity will be likely to appear.

Two risers, only one has piped.

In every case, each casting has two risers and only one has piped.

Two risers, one casting.

This riser piped.

This riser piped.

Step 12 SOLIDCast uses the THERMAL MODULUS to calculate the location and extent of feeding zones within the casting. This is superior to the traditional measure of Volume:Surface Area Ratio, as it is able to take into account heat saturation of mold and core pockets as well as heat extraction by chills and, if desired, temperature distribution due to filling.

Step 13 The SOLIDCast Cast Iron Riser Design Program assumes that side risers are cylindrical with a hemispherical bottom, while top risers are cylindrical in shape. Rule: The tops of the risers should be above the highest point of the casting for gray and ductile iron casting, by at least the minimum section thickness.

Step 14 Gating should be designed to freeze relatively quickly after the liquid metal has filled the mold cavity. In general, this means that the gate attachment to the casting should have a 5:1 ratio of width to height to ensure relatively quick freezing so that expansion pressure can be contained. Remember, Control of Expansion Pressure is our ultimate goal in feeding cast iron.

t = A/5

t = A/3

All of these calculations can be performed quickly and easily in

As an example, consider the task of designing a feeding system for the following ductile iron casting.

This is the basic casting shape as imported from a CAD system in SOLIDCast.

Ductile Iron is selected as the Casting Material from the SOLIDCast database.

The casting is meshed with no risers or gates, so that a thermal simulation can be run for calculation of the Modulus of the casting.

Once the thermal simulation is complete, the SOLIDCast Riser Design Wizard is selected

 and the user instructs the Wizard to calculate and display the Casting Modulus.

The Iso-Surface Plot is selected

 and from the Iso-Surface Plot Menu, we can read that the maximum Modulus of this casting is about 0.469 in. At this point, this is all the information we need from the Wizard, so we can just press Cancel to avoid making the plot at this time.

Another item of information well need is the weight of the casting. This can be easily obtained by selecting Mesh Weights from the main menu. Here we can see that the casting weighs 18.953 lb.

Now we are ready to calculate the properties of the iron, and the required riser size.

From the main menu, we select Tools Iron Property Calculator.

Here we enter the Carbon, Silicon and Phosphorus content of the iron.

Here we enter the casting Modulus as previously calculated by the Wizard.

And here we enter an estimate of the temperature of the metal in the mold.

Clicking the Calculate Iron Properties button causes the system to display the Shrinkage Time (ST) in terms of % Solid, and the net amount of Expansion (+) or Contraction (-) which occurs up to that Shrinkage Time. This is the quality of the iron without considering mold dilation.

Now that we have the properties of the iron calculated, we can design a riser for this casting.

First, we enter the casting weight as previously calculated by the system in the Mesh menu.

Next, we select the expected amount of mold dilation. This can be anywhere from less than 0.5% for a very rigid mold to more than 2% for a loose green sand mold. Here weve selected 1% for a well-made sand mold.

The next item to select is sleeve type. You can select either a sand riser (no sleeve), an insulating riser, exothermic or exothermic mini-riser. You can also select whether the casting is gated through the riser. The proportion of liquid metal removed from the riser is automatically adjusted.

Next we select the ratio of Height to Diameter that we want to use for the riser design.

Finally, we have the option to select either a Top or Side Riser. Here we have selected a Side Riser.

Now, pressing the Calculate button will display the required riser and neck size, as well as the Modulus of the neck and the riser. Note that the Neck Modulus is also referred to as the Transfer Modulus and can be used to indicate how many feeding zones (and now many required risers) there are for this casting.

Notice that by selecting the Short Neck option and repressing the Calculate button, we can calculate a neck size for a riser which is very close to the casting (closer than the minimum dimension of the neck).

Now by plotting the Transfer Modulus in an X-Ray View (Iso-Surface Plot) we can see that the entire casting is one feeding zone, so only one riser is required for this casting.

Another image of the Transfer Modulus, using CastPic plotting, also shows one zone which means one riser is required for this casting.

A more traditional Modulus calculation using Volume/Surface Area Ratio would have indicated two separate feeding areas, one in the central hub and one around the outer rim as shown here. Why is there a difference?

Heat Saturation

This cross-sectional view through the casting and mold shows temperature. You can see that the mold material becomes saturated with heat in the pocket areas between the inner hub and the outer rim, which keeps the thinner sections hot. This effect would not be captured by performing the old-fashioned Volume/Surface Area Modulus calculations, but is automatically taken into account when performing the Thermal Modulus function within SOLIDCast, because thermal effects in the mold are simulated.

Now that we have the riser and neck dimensioned, we also need to dimension the sprue, runner and gate, as well as estimate a fill time. The SOLIDCast Gating Wizard calculates an Optimal Fill Time of about 13 seconds for this casting (assuming a single casting).

And by describing the geometry of our proposed gating system

The Wizard calculates for us a sprue diameter of about 0.575 in.

And an inlet gate of about 0.23 in. x 1.13 in., which should ensure that the gate freezes quickly for control of expansion pressure.

Now we can use all of the calculated dimensions to create a simple system for gating and feeding this casting, which would appear as follows:

The complete model: Casting, Neck, Riser, Gate and Sprue

We use the results of the Cast Iron Calculation Utility Program to adjust the shrinkage curve parameters for the exact conditions of this iron chemistry, temperature and modulus value.

Shrinkage Time of 63%, amount of shrinkage = -1.1% minus Mold Dilation of 1% for a total shrinkage of -2.1%.

Add expansion of approximately 0.5% per 10% solidification.

Set CFS Point approx. 5% to the right of the ST Point

Using FLOWCast, we first perform a filling simulation of the casting, pouring metal down the sprue, through the gate and riser and into the casting cavity.

Finally, we use SOLIDCast to perform a simulation of the solidification of the casting and to predict the soundness of the final part.

Progressive Solidification

Shrinkage Prediction

Shrinkage Prediction: X-Ray View

The Final Result A sound casting, correctly designed using the SOLIDCast Riser and Gating Design tools, and verified using SOLIDCast and FLOWCast simulation.

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Ladle Calculations
Allows you to calculate capacities, flow rates and fill times from a given ladle. This utility also interfaces to FLOWCast and allows fill simulation using variable flow rates from a ladle.

Mask Riser Density

Removes Material Density data from Riser Material areas so that you can see Material Density indications ONLY within the casting.

Plot SOLIDCast Fill Times

Allows you to plot fill times as calculated using the SOLIDCast (not FLOWCast) fill algorithm.

Project Viewer

Allows you to select any model, mesh or simulation in a project and display summary information about that item. For example, you can see exactly how a model was meshed for simulation, how many shapes are in a model, how long a SOLIDCast simulation took to run, and numerous other items of data.

QuickPlot
Lets you change the plot display quickly and easily. You can change the view, resolution and display method. You can also re-plot very quickly, to create a sort of animation.

Reduce STL File Size

This utility can be used to reduce the number of triangles, and thus the file size, of an STL file for easier loading and display in SOLIDCast.

Reset Simulation Stop Point

This utility is used to change the end point of a simulation in SOLIDCast. For example, you can initially run a simulation until the casting is solid, and later use the utility to change the end point when all metal is solid, or when the casting drops below a minimum temperature.

Riser STL Shape

This utility is used to create an STL file for a riser of given size and shape. The STL file can then be loaded into an existing model in SOLIDCast.

Scale Model Size

This utility can be used to scale the size of a SOLIDCast model up or down (larger or smaller) by a given scale factor.

Simulation Image Control

Allows you to adjust the view shown as a simulation runs. You can change the angle of the display, the resolution of the picture and how the solidifying nodes are displayed.

Simulation Parameters

This utility is used to set several simulation parameters that in previous versions of SOLIDCast had to be set by creating and editing text files in the installation folder. These files are still in use and can be adjusted by the user, but this utility simplifies their use.

SOLIDCast Settings System Info

This utility creates a display and a text file which gives System Information about your computer and your installation of SOLIDCast. This can be helpful to Finite Solutions in diagnosing problems or answering specific questions.

Solidification Time Gradient Calc

This utility calculates and places solidification time gradient calculations from a simulation into the Custom function so that they can be plotted. The Solidification Time Gradient has shown promise as a predictor of areas in a casting prone to hot tearing.

Split Files for Emailing

This utility is used to split large files into pieces so that they can be emailed (or placed onto media) and is also used to recombine the pieces. Many email systems still have limits on the size of attachments, which in some cases may be as small as 2MB. Video files created by SOLIDCast or FLOWCast will often be larger than this. The File Splitter Utility Program allows you to split these large files into pieces which can be emailed to another person and then recombined on the other end.

STL From Model

This utility allows you to create a single STL file of a SOLIDCast model, no matter how many shapes were used to build the model.

STL Slice

This utility is used to create a 2D slice at a given point through a binary STL file. The slice can be in the XY, XZ or YZ orthogonal planes. The output 2D data can be either DXF format, or in AFSCad format. This is often useful for establishing exact dimensions or locations of features on STL shapes.

STL of Intersecting Cylinders

This is a special-purpose utility which creates an STL file representing an intersection of two cylinders with a fillet radius around the intersection, like this:

Two Stage Pour

This utility is used to set up a file that can be used by FLOWCast for a two stage pour process. For example, you could do the first 90% of filling from the sprue, pause for a number of seconds, then finish filling by pouring hot metal into the top of a riser.

For More Information:

Contact Dave Schmidt: Dave@finitesolutions.com 262 644 0785 Or Larry Smiley: Larry@finitesolutions.com 513 737 7300