adstefan ver.2016 tutorial [no.1] die casting ... ②the runner area num:17,668, ... calculation of...

© Hitachi Industry & Control Solutions, Ltd. 2016. All rights reserved.[Die Casing Method] Flow_Solidification

ADSTEFAN Ver.2016 Tutorial [No.1]

Fluid Flow AnalysisSolidification Analysis(Die Casting method)


The explanation about the operation of the fluid flow analysis and solidification analysis for High Pressure Die Casting Method.

1

Preface

Contents


The Flow of ADSTEFAN Tutorial

2

Input the model(STL format)

Fluid Flow

Solidification

Analysis Condition

Generation of Mesh

3. Reviewing Results

1. Setting input data

2. Executing Analysis

The Displaying results


1‐1 The Model for Analysis

3

Inflow Direction

Gravity Direction

The model’s shape for this tutorial : 1_flow01_fan.stl


1‐2 Creation of New Projects

4

①By clicking the button , the screen for creating a new project will be activated.

②Assign the folder for saving a new project.

③Input project file name as“Diecast(flow_solid)”.

④By clicking the button [OK], a new project will be created.


1‐3 Inputting STL File for Analysis

5

②By clicking the button , the window for STL file will be opened.

①Click the menu [Model].

④By clicking the button [Open], set STL file.

STL File

③Select the inputting STL file(1_flow01_fan.stl).


1‐4 Outline of Setting Window for Auto‐meshing

6

Setting mesh generation condition, such as Mesh Width, Direction of Auto Gate, Offset, etc.

The list of selected STL file is displayed.In the area, set several items(Parts Name, Attribute, Material Name, etc.) in each STL file.

The Shape for STL fileis displayed.

© Hitachi Industry & Control Solutions, Ltd. 2016. All rights reserved.[Die Casing Method] Flow_Solidification 7

1‐5 Setting Items in Each STL File

File Name The inputted STL file name are displayed.

Parts Name Assign the parts for each inputted STL file. In initial state, these parts names are set as “3.casting”.

Attribute Assign the attributes such as casting, mold, gate, etc..※1.Dummy, 2.mold, and 3.casting cannot be changed from initial state.

Material Name Assign used material name. Each material name can be selected from pre‐registered database in ADSTEFAN.

Occupation Assign the criteria for meshing as the parts name in each element.

Order If inputting multiple STL files, set the order for meshing in each STL file. Parts Name which is meshed by the rear STL file will be overwritten, when the shapes of the model are duplicated in each element.

Folder The folder which save each STL file is displayed.

Several items are set in each selected STL File.


1‐6 Setting Each Parts Name and Material

1.dummyThe parts name “1.dummy” is defined in each outermost layer, the temperature will be unchanged. The material set in the element depends on the range of meshing in the model.

2.moldThe area which are not directly meshed by inputted STL file will be automatically defined as “2.mold”.

The range A → Select the material as air (including main mold)

The range B → Select the material as the main mold.(including liner mold )

The range C → Select the material as the liner mold.(only mold area around the casting)

The range C is adopted in this tutorial.


1‐7 Setting Each Attribute and Material Name

③Select the Attribute as“3.Casting”.

④ Select the Material Name as “ADC12(AA383)”.

Setting Attribute and Material Name in each STL File

①Select the Material Name as “SKD61_Mold” in the tutorial.

② Select the Material Name as “SKD61_Mold”.

Setting Material Name in “1.dummy” and “2.mold”


1‐8 Setting Mesh Generating Condition(1)

CAD Units, Mesh Width

①Select CAD Units as “mm”.

②Select Mesh Width as “1.0mm”.

[CAD Units]：Select the units of the inputted STL file

[Mesh Width]：Input mesh width as 1/3 of the thickness of gate or thin portion.At first, relative large value will be preferable, gradually by decreasing mesh size, execute minute analysis.



Direction of Auto Gate

The inflowdirection

[Direction of Auto Gate]：Set the direction of molten metal’s inflow.At the outermost layer of assigned direction, gate elements are automatically generated.

At the outer most layer “‐Z”,gate elements are generated.

Select the direction as “‐Z”.



Offset

The range of analysis

Set these values as “20”(20mm÷1mm).※In the auto gate’s direction, the offset cannot be set.

mold

cast

[Offset]：Set the thickness of mold as the unit [mm]. Generally, when the STL file by mold is not inputted,offset will be set.※In case the STL file by mold is inputted,

you don’t need to set the offset.

In the case study, the range of mold is assumed as the outside of the products as follows.In ADSTEFAN, set the sufficient thickness of mold for solidification of all products.・The case of die mold : two to four times as the casting.・The case of sand mold: one to two times as the casting.

※If the thickness of mold are thin, the cooling in product will not beenough, so the products will not be solidified.


1‐11 Execution of Mesh Generation

②After confirmation, click the button [Yes], mesh is generated.

After the completion of mesh generation,the window by mesh information will be displayed.

① By clicking the button [Generate Mesh],the confirmation window will be opened.


1‐12 Mesh Window

Mesh distribution is displayed

Each item about mesh informationis displayed. Some items can be alsochanged.


1‐13 The Check of Mesh Information(1)

The tool for checking mesh dataIf some inconsistent meshes exists in the area, the analysis cannot be normally executed.In ADSTEFAN, the tool for checking the inconsistency of all meshed are provided.

①In Setting View, click the menu [Check].

②Click the button [Search].

If some inconsistent meshes aredetected, they are displayed as the list of Incompatible Mesh.

In case, by clicking the button[Change], they can be modifiedautomatically.

[Dummy Element Check]In the outermost area, except for dummy, gate, and vent cannot be set. In the function, we can check whether dummy elements are not included.


1‐14 The Check of Mesh Information(2)

After selecting [Parts Name] as “3.casting”, click the button [Search].

In Mesh Group area, the result bysearch is displayed.

If the number of groups is multiple,then meshes around detected groupneed to be checked and modified.

By the function, isolated meshescan be also modified. If the number of mesh in each group are less thanten, the module can be utilized.

[Isolated Element Check]When the product is divided into multiple parts, molten metal cannotbe filled completely in fluid flow analysis. So, check whether all casting elements are not isolated.


1‐15 Setting Analysis Condition(Casting Method)

②Set some items as follows.[Select Casting Method]：

Pressure Die Casting[1st Analysis]：

Fluid Flow[2nd Analysis]：

Solidification

[Link Initial Temperature][ON]：The temperature by first

analysis will be referred in 2nd analysis.

[OFF]：The temperature by each analysis will be not referred in the next analysis.

①Click the menu [Analysis Condition].

By default, Link Initial Temperaturewill be set as [ON].


1‐16 Setting Analysis Condition(Material Property)

②By clicking the top linecell, the window [MaterialSelect] is opened.

Each value can be inputted directly.

①Click [Material Property Setting].

The property in each material is displayed.

In the tutorial, all setting items don’t need to be changed.

The material list registeredin the database is displayed.To change the material,after clicking arbitrary Material, click [OK] button.


1‐17 Setting Analysis Condition(Fluid Flow)

②[Temperature Calculation]Select “ON”.

④[Analysis Item]Select “Standard Fluid Flow Analysis”.

⑥[Gravity]Set “‐Y Direction”.

⑤[Calculation Control]Set the condition for finish.Select “Filling Ratio”, set the value as “95%”.

①Click the menu [Fluid Flow].

③[Solver Type]Select “Standard Fluid Flow”.


1‐18 Setting Analysis Condition(Inflow)(1)

Click the menu [Inflow] in [Fluid Flow].

The velocities in the each fill ratio are inputted.

The values are displayed as the graph style.

The filling time corresponding to settingvelocity will be displayed.


1‐19 Setting Analysis Condition(Inflow)(2)

Inflow condition about the molten metalSetting velocity in the gate area. In the tutorial, the molten metal’s velocities are introduced from the

pouring condition of the plunger. Velocity(Low Speed) 0.2m/s

Velocity(High Speed) 2m/s

The changing timing In timing of the molten metal reaching the gate area, accelerate.

①Products/OverflowNum:29,721, Vol:29.721cm3

②The runner areaNum:17,668, Vol:17.668cm3

Filling ratio= ②/(①＋②)*100= 37.28%

The setting values are as follows from the previous analysis’s calculation.

The entrance ofProducts

Gate Element

Calculation of the filling ratio in the changing timing of velocity from the number of mesh.


1‐20 Setting Analysis Condition(Heat Resistance)(1)

②[Heat Resistance]Set each values as follows.

[1.dummy/2.mold]：(Same)20 (cm2・℃・s/cal)

[2.mold/3.casting]：(Mold/Casting)5 (cm2・℃・s/cal)

Material1 Material2 Heat Resistance (CGS)

Die Air 1000 ~ 2000

Casting Die 3 ~ 8 (Flow)

Casting Die 15 ~ 20(Solidification)

Mold Cooling water 0 ~ 16

<Sample values(High Pressure Die Casting)>

①Click the menu [Heat Resistance] in the [Fluid Flow].


1‐21 Setting Analysis Condition(Heat Resistance)(2)

Heat Resistance between “Dummy” and “Mold”“Dummy” elements are arranged in outermost layer, and the temperature in these meshes is constant.Heat resistance between “dummy” and mold depends on the analyzing range.

In range AThe contact with air is considered,it will be assumed between 1000 and 2000.

In range BThe contact with main mold is considered,it will be assumed about 20.

In range CSetting the thickness of mold around casting, it will be assumed about 20.

・The required thickness for solidifying castingDie mold ： 2T ～ 4TSand mold： 1T ～ 2T

※T：Thickness of casting portion

Setting in the tutorial

The temperature in the Surface D-D’

The range‐C(Within the mold around casting)

The range ‐B(Within the nesting mold) The range A

（Within main mold）

D D’


1‐22 Setting Analysis Condition(Results Output)

③[Output Files]Select the following items.

・Filling Value・・・the filling situation in each mesh.・Filling Temperature・・・the temperature of

the molten metal.・Air Volume・・・the air Volume in each mesh.

②[Frame Number Setting]set each values as follows.Filling Ratio(%) Frame Number

095

By the above setting, each analysis results will be outputted every 4.75%. The initial state will be also outputted, so the total number of the outputted frame number will be 21.

20

①Click the menu [Analysis ResultsOutput] in the [Fluid Flow].


1‐23 Setting Analysis Condition(Solidification)

②[Select Analysis Item]Set some items as follows.[Analysis of Shrinkage Cavity]：ON[Pseudo‐pressure calc.]：ON[Inlet Flag]：ON[Method]：Micro Porosity

④[Gravity Direction]Set as “None”.

①Click the menu [Solidification].

③[Calculation Control]Set the condition for finish.Select “Solidified Ratio(%)”,set the value as “100%”.


・Supplying from the top part’s mesh in the group.・In case gravity is not assigned, supplying from the maximum temp. mesh.・In connection with gate, supplying from out of gate.

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The Prediction method of Shrinkage Cavity ●PrincipleBy calculating the shrinkage and supply of molten metal every the time step Δt for solidification analysis, we are calculating the soundness of each casting elements. Soundness : 100% ⇒ shrinkage hole : 0%, Soundness : 0% ⇒ shrinkage hole : 100%

1‐24 Setting Analysis Condition(Shrinkage Cavity)

Phase‐1：Solidus ratio is less than fs<Pseudo‐pressure OFF>

Phase‐2：Solidus ratio is not less than fs

<Pseudo‐pressure ON>

・Supplying from neighboringtop and high temp. mesh.・If gravity is not considered,supplying from maximum temp. meshes.

<Method 1>No supplying, so theshrinkage will be remained.

<Method 2, Micro Porosity>Supplying from neighboringhigh temp. meshes, the volume of supplying depend on the value of solidus ratio.

[Shrinkage cavity]：ON[Pseudo‐pressure calc.]：ON[Inlet]：ON[Prediction Method]：Micro Porosity[Gravity Direction]：No Setting

<General Setting>


1‐25 Setting Analysis Condition(Heat Resistance)

②Select [Fluid Flow] in the pull‐down menu [Reading Data from Other Analysis].

※Heat Resistance set in fluid flow analysis will be imported.

①Click the menu [Heat Resistance] in the[Solidification].


1‐26 Setting Analysis Condition(Results Output)

③[Output Files]Select the following items.

・Solidus Ratio(4 Grade)・Solidifying End Time・Degree of Soundness

②[Frame Number Setting] set each values as follows.

Solidified Ratio(%) Frame Number0

100

By the above setting, each analysis results will be outputted every 5%. The initial state will be also outputted, so the total number of the outputted frame number will be 21.

①Click the menu [Analysis ResultsOutput] in the [Solidification].

20


2‐1 Executing Analysis(1)

①Click the menu [Execute Analysis].

②Click the button [Yes], in thedisplayed the saving confirmation window. After saving, the windowfor executing analysis will be opened.


2‐2 Executing Analysis(2)

By clicking the button [Execute], the analysis will begin, the button will be changed from [Execute] to [Break].

Before Execution Under Execution

The list of Analysis Type are displayed.

The log information by analysis is displayed.

Progress status and elapsed time are displayed.

By clicking, the analysis will be suspended.

The detailed items about each analysis are displayed.

Project Name, Status are displayed.


3‐1 Displaying Analysis Results

①After finishing the analysis, by clicking the button in the Project Explorer the menu [Analysis Results] will be displayed.

② By clicking the each item in the menu [Analysis Results], the selected analysis result is displayed.


3‐2 The Example of Evaluation of Analysis Results(1)

The Filling Ratio at final frame The Residual Air at final frame

・The Air entrapment can be confirmed in the center of products.⇒ The possibility of pin hole and blow hole is considered.

・The final filling area is not in overflow portion, the casting plan need to be investigated again.

Fluid Flow Analysis


3‐3 The Example of Evaluation of Analysis Results(2)

Solid Ratio at 10th frame Soundness at final frame

・In the process of solidification, directional solidification begins to break. ⇒ There is a possibility of shrinkage porosity. ・The area which the directional solidification is broken off can be detected shrinkage porosity.

Solidification Analysis

adstefan ver.2016 tutorial [no.1] die casting ... ②the runner area num:17,668, ... calculation of...

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