1 Check better resolution by Retained Melt Surface (RMS)
Experiment Retained Melt Surface
trace of retained melt (=isolated liquid)
Movie File AA’
Choose more accurate Shrinkage Model (Niyama, M-Niyama, Feeding Eff.)
Optimize shrinkage parameters (G, R, V and a, b, c)
Experiment Niyama
1 Niyama : (Ga / Rb)c a=1.0, b=0.5, c=1.0
2 Modified Niyama : (Ga / Rb)c a=1.0, b=0.5±α, c=1.0±β
3 Feeding Efficiency : (Ga / Vb)c a=1.0, b=1.0±α, c=1.0±β
Standard
Interface Moving Velocity (V)
Shrinkage Possibility → Shrinkage Probabilistic Model
Shrinkage Probability (Psh)
Accumulated Frequency (ω)
Shrinkage Size
Experiment Hot Tearing Intensity
Hot Tear Intensity : (ISFCa / RMMb)c a=1.0±α, b=1.0 ±β , c=1.0 ±γ
Iso-Solid-Fraction Curvature (ISF) Retained Melt Modulus (RMM)
Predict it using Hot Tear Intensity
Predict center line crack in various ingots using Hot Tearing Intensity
Optimize hot tearing parameters (ISFC, RMM and a, b, c)
Ingot, 13 Ton
Predict shrinkage, phase & mechanical properties according to composition
Input Composition
Carbon : 0.4%
Cr : 5.1%
Si : 0.95%
Mg : 0.35%
Mn : 0.15%
P : 0.03%
S : 0.03%
Mo : 1.5%
Consider Natural Convection during Solidification
Calculate natural convection in mushy zone during & after filling of 100%
It changes composition in mushy zone and accelerate segregation
Solidified Vol. 37% Solidified Vol. 89%
Temperature Temperature
12
Calculate diffusion of components & natural convection in mushy zone
Predict segregation of major components (C, P, S, Mn) all at once
Segregation Prediction
2 Diffusion & Segregation in Mushy Zone
3 Solidification & Shrinkage
Calculate diffusion of components & natural convection in mushy zone
Predict segregation of major components (C, P, S, Mn) all at once
Segregation Reducing Evaluation
segregation, such as increase in filling time,
more height for riser or exothermic powder,
and additional pouring
Ingot, 20 Ton
Enhance Feeding of Riser by Exothermic Powder
Exothermic powder can be set on top of riser without 3D modeling
Set exothermic conditions : ignition time, heat flux by time, etc.
Insulation
Sleeve
Riser
Exothermic
Powder
You can optimize exothermic layer’s Thickness, Type, Conditions
Quantitative comparison of exothermic powder models
Shrinkage Size Model +
No Exothermic
You can add pouring for decreasing Segregation and Shrinkage
Optimize pouring temperature, time, composition (C, P, S, Mn)
1st Pouring
You can add pouring for achieving expected Segregation profile
Optimize pouring temperature, time, composition (C, P, S, Mn)
General Pouring Additional Pouring
You can analyze the path of Slag & Oxide inclusions
Modify pouring & lining conditions for reducing
Slag & Oxide
reactions during the melting process
Ingot, 45 Ton
You can quantitatively compare pouring conditions based upon gas amount
Check the location & reason of gas entrapment
Gas Amount
Standard Deviation
(unit : cc/100g)
= 0.93420 cc
The Management
Propose Gating Design for each Tonnage
Gating Design has been accumulated for each Tonnage past 20 years
We can propose the better Gating design for each Tonnage
1.5 Ton 3 Ton 8.5 Ton
11 Ton 13 Ton 30 Ton More..
100~500 Ton
Propose Mold Design for each Tonnage
Mold Design has been accumulated for each Tonnage past 20 years
We can propose the better Mold design for each Tonnage
Sleeve
Mold
Base
Dramatically Decrease Calculation Time
Over 100 ton large ingot with over 2 mill. mesh & 30 days. filling time
Fast Ingot Solver dramatically save calculation time, 10 times more
Ingot, 510 Ton
Auto Mesh
Find the best meshing condition automatically (dramatically save human time)
Check thin sectioned areas automatically
Check Thin Section Area using Cross Section
More Mesh
Make PowerPoint Report more Efficiently & Quickly
You can save Post Results automatically for PowerPoint in anyPOST
Please set What Results to be saved automatically
Setting Data
(movies, images)
You can do Post Processing on PowerPoint File
Observe results from various Angles / Cross sections without running Post
Enhance efficiency of Reporting and Sharing simulation results
Real Post on PowerPoint
Import Results from Post
Cross Section
Movie File
Multi-results can be combined and analyzed using Logical operations
You can make a new Combination to observe the best results
Result A (Niyama Criterion) Result B (Feeding Efficiency)
Logical Operation
A B
Micro Porosity
(Intersection of
General Database : provide 600 alloys, freely modify & make user DB
Alloy Composition : Thermodynamically calculation, Phase information
General Database Alloy Composition