training overview solidcast
TRANSCRIPT
![Page 1: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/1.jpg)
Casting Process Design
From Start to Finish
Version 7.2.2 System Overview
6/23/09
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What are the goals of Casting ProcessDesign?
• Make good (acceptable) castings
• Make them right the first time
• Make them in the most efficient way possible
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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
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What this means to the foundrystrategically:
• Higher profitability
• More customer responsiveness
• Better overall customer relationship
• Better market position
• Ability to fend off competition
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The spectrum of foundry activity
Marketing
Process Design
Productionmanagement &
control
Strategic Planning
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The pieces of process design
CustomerSpecs and Data
Initial DesignConcepts
DesignVerification
DesignOptimization
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The pieces of process design
CustomerSpecs and Data
Initial DesignConcepts
DesignVerification
DesignOptimization
CAD Import
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The pieces of process design
CustomerSpecs and Data
Initial DesignConcepts
DesignVerification
DesignOptimization
Riser DesignGating Design
CAD Import
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The pieces of process design
CustomerSpecs and Data
Initial DesignConcepts
DesignVerification
DesignOptimization
Riser DesignGating Design
CAD Import
Flow AnalysisSolidification
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The pieces of process design
CustomerSpecs and Data
Initial DesignConcepts
DesignVerification
DesignOptimization
CAD Import
Riser DesignGating Design
Flow AnalysisSolidification
Optimization
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Integrated “Up-Front” Design Tools
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The Riser Design Wizard™
Automatic sizing and location ofrisers
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Traditional Approach
Modulus =Volume
Surface Area
New Approach
“Thermal” Modulus calculated fromsolidification analysis of “naked” casting
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The Gating Design Wizard™
Automatic calculation of gatingcomponent sizes and Optimal Fill
Time
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Horizontal Gating
Ref: Basic Principles of Gating Design (AFS)
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Vertical Gating
Ref: Modern Casting Tech Report 755 (Disamatic)
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Design Verification
Finite Difference Solidification Modeling
CFD (Computational Fluid Dynamics) Flow Modeling
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Design Optimization
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The Basic Simulation Process
1. Select alloy and mold materials.
2. Import model shapes from CAD, or create shapes withinSOLIDCast, for the casting, risers, gating, sleeves, chills,etc.
3. Mesh the model, and run the simulation.
4. Plot the results, looking at progressive solidification andprediction 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 toStep 3 again.
6. If results are satisfactory, you are done.
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Some Basic Points
• SOLIDCast deals with 3D models. This means we need tobe 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 ofmodels, meshes and simulations. Usually a project refersto one part number, and the various design iterationsassociated with that part. The steps in the project areshown on the left side of the SOLIDCast screen – this isthe “Project Tree”
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Blocks
Creating Basic Shapes
SolidCylinders
SpheresHollow
Cylinders
Enter Dimensions
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Creating Solids of Revolution
DXF File fromCAD System
Specify Axis ofRevolution and
Degrees ofRotation
ADG File fromAFSCad
Sketch ShapeOn-Screen
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Creating Solids of Extrusion
DXF File fromCAD System
Specify Limitsof Extrusion
ADG File fromAFSCad
Sketch ShapeOn-Screen
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STL File
STL File
IGES, STEP,etc.
FileConverter
Note: A File Converter may be a CAD system (examples: SolidWorks, SolidEdge,ProEngineer) or a viewing/conversion program such as SolidView.
Importing 3D Shapes from CAD
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“Composite” Models
Solid Cylinder
Solid ofRevolution
Block
Solid ofRevolution
Solid ofRevolution
Solid ofExtrusion
STL File
Solid Cylinder
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Importing Files from CAD
Required File Format: STL (Binary)
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1. Start SOLIDCast
2. Select File… New Model
3. On the Tool Bar, click “Add a shape to theModel”
4. Click the “down” arrow on the Shape Typefield. Move to the bottom of the list of ShapeTypes 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 andselect “Zoom Full”
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Questions
What’s 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 don’t know, open the file in Windows WordPad. Ifyou can read it, it’s ASCII. If not, it’s binary.
What about units – Inches and mm?
If your system is set to English units, SOLIDCastassumes the STL file is inches. If in metric units,SOLIDCast assumes it’s mm. Before selecting the file,you can specifically select inches or mm on the AddShape window. After importing, you can checkdimensions just by clicking on a couple of points. If it’swrong, delete the shape and re-import.
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Questions
What do I do if I only have an ACSII STL file?
Use the SOLIDCast STL Convert Utility Program toconvert the ASCII file to binary.
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Creating Basic Shapes inSOLIDCast
Cylinders, Hollow Cylinders, Spheresand Rectangular Blocks
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1. On the Tool Bar, click “Add a shape to theModel”
2. Click the “down” arrow on the Shape Typefield. Select the type of shape you want tocreate.
3. Enter the required coordinates anddimensions, and select the material type.
4. Click the “Add Shape” button.
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Questions
What if I enter the wrong dimensions, or want to changesomething later?
You can select the shape, and then select Edit… EditSelected Shapes and change the shape parameters.
What is the Priority Number?
Priority numbers are important ONLY when two shapes ofDIFFERENT MATERIAL overlap. The shape with thelowest Priority Number ends up in the overlap region.
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Questions
What is the difference between Casting Material and RiserMaterial?
They are both casting alloy, and act exactly the sameduring the simulation. The main difference is that thesystem will display a different weight summary for eachmaterial type, so you can break the total metal weight intothe casting and the rigging, to calculate yield.
Also, you can specify a different HTC at the riser/moldsurfaces and the casting/mold surfaces, in permanentmold simulation, when you use these different materialtypes.
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Sketching Shapes on theScreen
For making solids of extrusion orrevolution.
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1. First, you can (optionally) set the “Snap” byselecting “Tools”, “System Parameters”,“Model & Sim”… then enter a “Snap to Grid”dimension.
2. On the Tool Bar, click “Add a shape to theModel”
3. Click the “down” arrow on the Shape Typefield. Select the type of shape you want tocreate, either Revolved or Extruded.
4. Start sketching on the screen.
5. Click the check mark on the Tool Bar to closethe shape.
6. Enter the shape information in the window.
7. Click “Add Shape”
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Selecting Shapes to Edit
You can move, rotate, copy, hide,group, ungroup, edit properties or
delete selected shapes.
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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 shapewill turn a different color (usually red) toindicate that it is selected.
3. You can select MULTIPLE SHAPES bypressing the Ctrl key when you click on theshapes.
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Moving Selected Shapes
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1. Once shapes are selected, then select “Edit”and Move Selected Shapes.
2. You can enter X, Y or Z distance to move theshape.
3. You can move the shape around using mouseclicks in an orthogonal view.
4. You can move a shape from one “Pick Point”on a surface to another “Pick Point”.
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Copying Selected Shapes
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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 fromthe original at a given X,Y,Z offset distance…or…
3. You can perform a Ring Copy, which creates aseries of copies, spaced evenly around anaxis (for example, every 30 degrees aroundthe Z axis would result in 11 copies of theoriginal shape, plus the original).
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Editing Selected ShapeProperties
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1. Once a shape is selected, then select “Edit”and Edit Selected Shapes.
2. You can alter any shape characteristic whichappears in the window.
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Hiding Selected Shapes
Sometimes it is convenient to hide oneor more shapes so that you can moreclearly see other shapes in the model.
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1. Once shapes are selected, then select “Show”and Hide Selection.
2. Later, to display hidden shapes again, select“Show” and Show All.
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Selecting Casting Alloys
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1. Select “Model” and then “Materials List” fromthe 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 InitialTemperature.
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Setting Cast Iron Properties
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1. You will need to know Carbon, SiliconPhosphorus content as well as CastingModulus and Temperature in the mold. If youdon’t know the Casting Modulus, use theRiser Design Wizard on the casting shape.
2. Run the Iron Property Calculation (VDG.exe)Utility Program to get % solid and amount ofexpansion/contraction.
3. In SOLIDCast, select Model… Materials List…Casting. Select an iron alloy (for example, CIDI Ferr for Ductile Iron).
4. Now select the Curves tab.
5. Click the Ductile Iron button.
6. Enter Carbon & Silicon to generate coolingcurves.
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7. Click on the Draw Shrk Curve button.
8. Locate the point with the % solid andexpansion/contraction from the VDG program.For mold wall expansion, add 1% or 2%contraction. Click on this point and then clickDone.
9. Click on Set CF Solid Pt button and move theCFS line to the % solid calculated by the VDGprogram.
10. To save this, go to the Casting tab, enter aunique name, and click the Add to DB button.
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Selecting Mold Materials
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1. Select “Model” and then “Materials List” fromthe 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 inthe model. To select materials from theDatabase, use the slider bar, select thematerial, then click “Add to list”.
4. You can add as many materials as you want tothe list on the right. SOLIDCast will maintainthis list until you change it.
5. To remove a mold material from the list,highlight it and click “Remove from list”.
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Component Files
You can select any or all shapes within a model, andmake a Component File. This can be used to create
a library of standard shapes (like risers, or gatingcomponents, or chills) so you don’t have to recreate
these multiple times.
This can also be used to make a file of a completecasting model, to transfer to another computer.
Component Files contain both the geometry and thematerial properties of the selected shapes.
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1. Select the shapes you want to make aComponent File out of… or select Edit…Select All Shapes to get the whole model.
2. Select Model… Export… Selection and enter aname 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 thenselect the file. This will bring these shapesinto the new model.
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Planes of Symmetry
Planes of Symmetry can be used to section aSYMMETRICAL MODEL along center lines. This
allows you to simulate one-half or one-quarter of thecasting to save time.
Later, you can use the Mirror function to mirror thedata back into the portions of the model which were
not simulated (this step is optional).
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1. Select Model… Options… Planes of Symmetry
2. Select the Plane you want to activate (lower orupper X, Y or Z)
3. Enter the location (if it’s not 0)
4. Press the Activate button.
5. Meshing and simulation will occur only onthose portions of the model which are not cutoff by the Planes of Symmetry.
6. After running the simulation, if you want tomirror results, select Simulation… Mirror.
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Filling Simulation
SOLIDCast will perform a simple filling simulationwhich shows progressive temperature loss of the
liquid metal during filling of the cavity.
You need to specify the Fill Time (or calculate it withthe Gating Design Wizard) and place Fill Material at
the entry points for the liquid metal.
For a more advanced fill calculation which showstemperature and velocity using true CFD fluid
simulation, see the FLOWCast optional module.
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Setting the Fill Time• Select Model… Materials List… Casting
• At the bottom of the screen, enter the FillTime.
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Placing Fill Material• Create a shape at the entry point of the liquid
metal. Usually, this will be a cylinder at thetop of the sprue. It may also be just gatesattached to the casting. The shape must belarge enough to be meshed with at least onerow of nodes.
• Under Material Type, select Fill Material.
• Where the Fill Material touches Casting orRiser Material, the filling simulation will begin.
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Cloning a Model
If you want to make a copy of a model, for thepurpose of making a change and running a newsimulation, use the Clone Model feature. This
creates a duplicate model which you can edit andchange.
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1. On the Project Tree, select the model you wantto clone.
2. Select File… Clone Model.
3. A new model will be created.
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Meshing a Model
Meshing is required before runningany simulation. This breaks the model
down into small cubical elements.
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1. Select “Model” and then “Create Mesh” fromthe 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.
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Weight Calculation
After meshing, the system will displayweights of all materials.
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1. Select the Mesh entry on the Project Tree.
2. From the menu, select Weights
3. A table of weights will be displayed.
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Running a Simulation
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1. Highlight the mesh on the Project Tree (the liston the left side of the SOLIDCast screen).
2. From the menu, select “Mesh” and then “StartSimulation”
3. To run a simulation under “normal”conditions, press OK.
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Sand Castings
• Normally, we neglect internal(material/material) HTC’s when performingsand casting simulation
• In the Materials List, select the HT Coefficientstab. Make sure the check box labeled UseInternal HT Coefficients is blank. For theExternal HT Coefficient, we normally use avalue of 1.5
• When meshing, normally we select aRectangular Mold.
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Sand Castings, Cont’d
• Select only as much sand thickness as youneed to absorb the heat (1-2” for smallercastings, 5-6” for large castings)
• Use Open Top if you have open risers, useClosed Top if you have blind risers
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Investment Castings
• Select Investment Shell for your moldmaterial. Set the Initial Temperature of theshell 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 tocreate an STL file representing the shell
• After meshing, be sure to use View Factorcalculator to account for radiant heatexchange. Select Mesh… View FactorCalculation.
![Page 71: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/71.jpg)
Investment Castings, Cont’d
• Why use the Shell Maker? If you have thingswhich are external to the shell such asinsulating wrap on the gating, or a bed ofvermiculite in which the shell is submerged,creating a shell as part of the model makes iteasier to accurately create the model.
• To use ShellMaker, you must have an STL fileof the casting AND the gating. If parts of themodel were created with SOLIDCast basicshapes, you can create an STL file using theSTL from Model Utility Program.
![Page 72: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/72.jpg)
Investment Castings, Cont’d
• From the Tools, and select the Shell MakerUtility Program. Specify the STL file and thesurface quality. This will create an STL filerepresenting the shell.
• Now, in SOLIDCast select Add a Shape, selectSTL and select the shell file. Designate it asShell Material, and give it a large PriorityNumber (like 8 or 9).
• Later when you mesh, select the None optionfor Mold Type (you already have a mold aspart of the model).
![Page 73: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/73.jpg)
Permanent Mold Castings
• Make sure that Internal HT Coefficients areturned ON (in Materials List, go to the HTCoefficient tab and click Use Internal HTCoefficients)
• Specify an HTC for each actual (physical)interface in the model. If two materials are incontact, there should be an HTC specified forthe surface between them.
• If the mold is rectangular in shape, you canuse the Rectangular Mold option in meshing.If you want a specific mold shape, that shouldbe created as part of the model, then selectNone under Mold Type in meshing.
![Page 74: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/74.jpg)
Permanent Mold Castings, Cont’d
• Make gates and risers out of Riser Material, sothat you can specify a different HTC at thosesurfaces than at the casting surface.
• If you can’t separate the gates and risers (ifthey are all one STL file) you can make twotypes of mold material, say Steel1 and Steel2.Make the mold of Steel1, and make insertsaround the gates and risers using Steel2, thenset up the HTC’s accordingly. Between Steel1and Steel2, use a very high HTC (say, 5000)which will thermally “join” these into onematerial.
![Page 75: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/75.jpg)
Permanent Mold Castings, Cont’d
• Mesh twice… once with fewer nodes (call this“Coarse” and once with more nodes (call this“Fine”). Ratio of nodes may be anywherefrom 1:4 to 1:10.
• When you run the simulation, specifyPermanent Mold as the Type, and select theCoarse mesh as the Warmup mesh.
• If you have FLOWCast installed, you canselect which filling algorithm to use for thewarmup cycles and for the final cycle.
![Page 76: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/76.jpg)
Permanent Mold Castings, Cont’d
• For aluminum permanent mold castings, werecommend using the $HTRED.410 file in theSOLIDCast folder. This is a text file containingthe number 0.30. This reduces the metal/moldHTC by 70% at the solidus point, per researchperformed by Dr. Sciama at Pechiney.
![Page 77: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/77.jpg)
Viewing Simulation Results
This is where you plot the results ofsimulations to look at progressive
solidification, riser feeding, shrinkagepredictions, etc.
This is done when the simulation iscomplete.
![Page 78: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/78.jpg)
1. Double-click the simulation on the ProjectTree (the list on the left side of the SOLIDCastscreen).
2. The Simulation Status window will appear.Close this window.
3. To plot results, click “Simulation” on themenu. Various options will appear.
![Page 79: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/79.jpg)
Plotting Options
Iso-Surface Plot: Plots one value as a 3D surfaceinside a transparent casting.
Cut Plane Plot: Plots on a 2D plane cut throughthe casting
CastPic Plot: Makes a 3D image of the casting,with data indicated by color mapping.
CastScan Movies: Makes movie (AVI) files usingmultiple, multi-colored iso-surfaces within thecasting.
![Page 80: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/80.jpg)
Example Iso-Surface Plot showingProgressive Solidification
![Page 81: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/81.jpg)
![Page 82: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/82.jpg)
![Page 83: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/83.jpg)
![Page 84: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/84.jpg)
![Page 85: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/85.jpg)
![Page 86: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/86.jpg)
Example Cut Plane Plot
![Page 87: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/87.jpg)
![Page 88: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/88.jpg)
Example CastPic Plots showingProgressive Solidification
![Page 89: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/89.jpg)
Solidification Pattern
![Page 90: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/90.jpg)
Solidification Pattern
Casting Sectioned on YZCenterline
![Page 91: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/91.jpg)
Solidification Pattern
Casting Sectioned on XZCenterline
![Page 92: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/92.jpg)
Example CastPic Plots showing Areasof Potential Shrinkage
![Page 93: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/93.jpg)
Casting Sectioned on YZCenterline
![Page 94: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/94.jpg)
Casting Sectioned on XZ Plane -7” from CL
![Page 95: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/95.jpg)
Casting Sectioned on XZ Plane 8” from CL
![Page 96: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/96.jpg)
Question: How do I capture theseimages for documenting simulation
results?
Use a screen capture utility such as Pizazz, whichallows you to set up the Print Screen key so that,each time you press the key, a new image file iscreated. These images can later be imported intoWord, PowerPoint, or other documentationprogram.
![Page 97: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/97.jpg)
Movie-Making Options
Iso-Surface Movie: Makes a movie of progressivevalues of Iso-Surface plots.
Cut Plane Movie: Makes of movie of progressivevalues on a 2D cut plane.
CastPic Movie: Makes a 3D movie image of thecasting, with data indicated by color mapping.
CastScan Movies:
Progressive: Movie of progressive values of adata item (usually progressive solidification)
Rotating: Rotating movie showing results(usually shrinkage defects)
![Page 98: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/98.jpg)
Plot Data:
Temperature
Shows the temperature in the casting (all plottypes) and in the mold (only 2D plots).
Temperature is shown AT THE TIME THAT THESIMULATION STOPPED. Normally, this is at the
end of full solidification.
![Page 99: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/99.jpg)
Plot Data:
Solidification Time
Shows the time, in minutes, at which each pointwithin the casting reached FULL
SOLIDIFICATION, i.e., the solidus point.
![Page 100: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/100.jpg)
Plot Data:
Critical Fraction Solid Time
Shows the time, in minutes, at which each pointwithin the casting reached the CRITICAL
FRACTION SOLID point.
The CFS point is the point at which the alloyloses its ability to flow liquid feed metal. This is
usually the best indication for looking atprogressive solidification, to see if any isolatedhot spots formed within the casting while it was
solidifying.
![Page 101: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/101.jpg)
Plot Data:
Temperature Gradient
Shows the Gradient, which is a measure of howmuch temperature was changing during
solidification over a distance in the casting. Unitsare ºC/cm.
Areas of low gradient tend to be “stagnant”solidification, areas with high gradient are usually
solidifying pretty well directionally.
![Page 102: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/102.jpg)
Plot Data:
Cooling Rate
Measures how quickly a casting was coolingduring solidification. Normally, rapid cooling isassociated with “better” materials properties:
Smaller grain size, more dispersed and dissolvedalloying elements, higher strength.
Units are ºC/Minute
![Page 103: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/103.jpg)
Plot Data:
Material Density
A measure of Macroporosity (macro shrinkage) inthe casting. Value ranges from 0 to 1. Lower
values are worse. Usually, the Critical Value isaround 0.99 to 0.995 (values below this indicate
visible shrinkage).
![Page 104: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/104.jpg)
Plot Data:
Niyama Criterion
A measure of Directional Solidification in thecasting. Low values are bad, high values aregood. A value of 0 means lack of directionalsolidification (usually a thermal center in the
casting).
Can be used to identify potential for centerlineshrinkage.
![Page 105: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/105.jpg)
Plot Data:
FCC Criterion
A measure of the potential for DispersedMicroshrinkage (Microporosity) in the casting, or
Secondary Shrinkage in iron castings.
The Critical Value is usually around 40% of thetotal range.
For example, if the range is 0 to 8, the CriticalValue would be around 3.2. Lower values are less
severe, high values are more severe.
![Page 106: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/106.jpg)
Typical Plot Sequence for Simulations:
• Look at various values of Critical FractionSolid to see the sequence of solidification,and to look for isolated hot spots.
• Look at Material Density in the range of 0.99-0.995 to highlight areas of potential shrinkage.
• Look at FCC Criterion at 40% of range, to lookfor tendencies for microshrinkage orsecondary shrinkage.
• Look at Niyama for possibility of centerlineshrink.
ISO-SURFACE PLOTS are fastest and easiest!
![Page 107: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/107.jpg)
Basics of Riser Design
Chvorinov’s 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
![Page 108: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/108.jpg)
Basics of Riser Design
(V/A) is referred to as theCasting Modulus
Casting sections with highmodulus solidify last.
Casting sections with lowmodulus solidify first.
![Page 109: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/109.jpg)
Basics of Riser Design
Shapes with high Modulus Shapes with low Modulus
![Page 110: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/110.jpg)
Basics of Riser Design
DirectionalSolidification
Lowest Modulus Highest Modulus
Increasing Modulus
![Page 111: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/111.jpg)
Using the Riser Design Wizard
![Page 112: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/112.jpg)
1. Import a 3D model of the casting.
2. Select alloy and mold materials.
3. You MAY elect to place gates to take fillinginto account.
4. Run a simulation of the casting with no risers.
5. Double-click the simulation on the ProjectTree (the list on the left side of the SOLIDCastscreen).
6. The Simulation Status window will appear.Close this window.
7. Select the Riser Design Wizard from the menu.
![Page 113: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/113.jpg)
An example of using the RiserDesign Wizard
![Page 114: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/114.jpg)
Using SOLIDCast, the typicalapproach to process design for a new
casting is to allow the system toanalyze a casting without risers and
determine the best suggested designfor risering.
This is done with the SOLIDCastRiser Design Wizard™.
![Page 115: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/115.jpg)
Here is an example casting model, imported as a 3Dshape from a CAD system.
![Page 116: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/116.jpg)
Using the Wizard approach, we firstperform a simulation of just the
casting, filled through the gates butwith no risers.
The results of this simulation appearas follows:
![Page 117: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/117.jpg)
Casting simulated with no risers
![Page 118: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/118.jpg)
Now, we run the Riser Design Wizard,which takes the results of this
simulation and suggests what risersare required.
![Page 119: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/119.jpg)
We start by telling SOLIDCast to “Design Risers”
![Page 120: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/120.jpg)
SOLIDCast has determined that 3 risers are required for thiscasting
![Page 121: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/121.jpg)
SOLIDCast then shows us each of thefeeding areas within this casting that
have been identified.
![Page 122: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/122.jpg)
Feeding Area 1
Feeding Area 2
Feeding Area 3
![Page 123: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/123.jpg)
Next, SOLIDCast shows us where theoptimum point of attachment for a
riser would be in each of these threeareas.
This point is the spot in each areawhich has the highest Section
Modulus.
![Page 124: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/124.jpg)
Attachment Pointfor Riser 1
Attachment Pointfor Riser 2
Attachment Pointfor Riser 3
![Page 125: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/125.jpg)
Finally, SOLIDCast suggests anappropriate size for each riser. Thiscalculation is based on both SectionModulus (volume/surface area ratios)and required feed metal volume for
each feed area.
![Page 126: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/126.jpg)
Here is the suggested design for Riser 1 (without a sleeve)
![Page 127: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/127.jpg)
And for Riser 2 (with a sleeve).
![Page 128: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/128.jpg)
And finally, for Riser 3 (also with a sleeve).
![Page 129: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/129.jpg)
Now, we add the suggested risers atthe suggested locations to the
SOLIDCast model.
![Page 130: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/130.jpg)
Riser 1 (No sleeve)
Riser 2 (Ins. sleeve)
Riser 3 (Ins. sleeve)
![Page 131: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/131.jpg)
Basics of Gating Design
Acceleration of Gravity:
g = 32.2 ft/sec2
H
V = 2gH
Objects in Free Fall
![Page 132: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/132.jpg)
H
Basics of Gating DesignLiquid Metal in Free Fall
V = 2gH
![Page 133: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/133.jpg)
Basics of Gating DesignFlow of Liquid Metal Through a
Channel (Runner or Gate)
Flow Rate (in3/sec) = Velocity (in/sec) X Area (in2)
Or
Area =Flow Rate
Velocity
![Page 134: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/134.jpg)
Using the Gating DesignWizard
![Page 135: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/135.jpg)
1. Run a simulation of the casting with no risers.
2. Double-click the simulation on the ProjectTree (the list on the left side of the SOLIDCastscreen).
3. The Simulation Status window will appear.Close this window.
4. Select the Gating Design Wizard from themenu.
![Page 136: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/136.jpg)
The SOLIDCast System also includesa program called the Gating Design
Wizard™.
This function analyzes the castingand alloy selected, calculates weight
of poured metal, suggests anOptimum Fill Time for the casting,and then details sizes of sprues,runners and gates for best filling.
![Page 137: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/137.jpg)
Let’s see how this would work…
![Page 138: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/138.jpg)
First, we specify the“class” of alloy we'repouring (in this case,Aluminum Alloy)
Next, the systemcalculates Pour Weightfor us.
Then, we describe the“Critical” (thinnest)section thickness.
And finally, the systemtells us the Optimum FillTime for this casting (inthis case, about 20 sec.)
![Page 139: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/139.jpg)
The next step is todescribe the sprueheight and the location ofthe gating relative to thecasting.
![Page 140: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/140.jpg)
This allows the system tocalculate an “EffectiveSprue Height” to use forgating calculations.
![Page 141: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/141.jpg)
Now, since we have two sprues,we’ll divide the weight in half foreach sprue and calculate theassociated gating (35 lbs ofmetal will go down each sprue).
The gating ratio (Sprue:Runner:Gate) canbe specified here. The ratio 1:4:4 isrecommended by AFS for most non-pressurized systems.
![Page 142: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/142.jpg)
Dimensions at top and bottom ofthe first sprue are given here.
![Page 143: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/143.jpg)
Dimensions of the runner priorto the first gate, and dimensionsof that gate, are given here.
![Page 144: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/144.jpg)
Dimensions of the next sectionof the runner, and the secondgate, are given here. Thisensures adequate and even flowto both gates.
![Page 145: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/145.jpg)
Now we consider the secondsprue, runner and gate.Dimensions of the second sprueare given here.
![Page 146: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/146.jpg)
And dimensions of the runnerand single gate are given here.
![Page 147: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/147.jpg)
Now, within a few minutes, we havecalculated all of the dimensional data
that we need in order to design thegating for this casting.
Let’s see how this would look on thefinal model…
![Page 148: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/148.jpg)
Sprue: .77 x .77 Top,.553 x .553 Bottom
Sprue: .77 x .77 Top,.553 x .553 Bottom
Runner: 1.5 x .815
Runner: 1.5 x .428
Gate: 1 x .642
Gate: 1 x .611
Runner: 1.5 x .815
Gate: 1.5 x .815
![Page 149: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/149.jpg)
Now, with the process design asprovided by the SOLIDCast RiserDesign Wizard and the SOLIDCast
Gating Design Wizard, we can run asimulation of the casting process
using SOLIDCast to verify the resultsof the design.
![Page 150: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/150.jpg)
Here is a plot of the sequential areas of solidification in thecasting.
![Page 151: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/151.jpg)
We can section this to view internal areas:
![Page 152: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/152.jpg)
In this view the predicted internal porosity is shown:
The casting has been produced with no internal porosity in thissection.
![Page 153: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/153.jpg)
And now we examine the casting with a horizontal sectionshowing progression of solidification:
![Page 154: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/154.jpg)
And the same view showing predicted internal porosity:
Again, there is no visible porosity in this section.
![Page 155: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/155.jpg)
With an “X-Ray” view we can see all internal areas of thecasting at one time, to determine that there is no porosityanywhere within the casting.
![Page 156: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/156.jpg)
The result:
By using the SOLIDCast processdesign tools, we have very easily and
quickly produced a design forproduction of this casting which will
result in a very sound cast part.
![Page 157: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/157.jpg)
Another Example of using theRiser Design and Gating
Design Wizards:
A “quick look” at a new casting.
![Page 158: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/158.jpg)
Casting Design
File: type_c_interim_ref.stl Dated: 04/15/03
![Page 159: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/159.jpg)
Analysis of Feed Areas &Required Risering
The Riser Design Wizard identified (6) distinctfeeding areas within the casting. In the following
images, each area is identified and thecalculated riser size is shown. Calculations are
based on a sand riser (no sleeves).
![Page 160: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/160.jpg)
Area 1: Requires 12” x 20” Riser
![Page 161: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/161.jpg)
Area 2: Requires 16” x 20” Riser
![Page 162: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/162.jpg)
Area 3: Requires 14” x 20” Riser
![Page 163: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/163.jpg)
Area 4:Requires 18” x24” Riser
![Page 164: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/164.jpg)
Area 5: Requires 16” x 20” Riser
![Page 165: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/165.jpg)
Area 6: Requires 14” x 20” Riser
![Page 166: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/166.jpg)
Calculation of Optimal Fill Time
Based on an estimate of total poured weight, andCritical Section Thickness (thinnest section of thecasting), the Gating Design Wizard estimates an
optimal fill time for pouring the casting.
![Page 167: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/167.jpg)
The Gating DesignWizard estimates a FillTime of 78 seconds forthis casting
![Page 168: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/168.jpg)
Once number of gates and sprue and runnerlocations are established, the Gating Design
Wizard can be used to calculate proper size forsprues, runners and gates for correct filling of the
casting cavity.
![Page 169: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/169.jpg)
Flow Simulation for Mold Filling
1. Models are generally built the same way you would buildthem for SOLIDCast simulation.
2. Normally we include the entire gating system whensimulating with FLOWCast.
3. Calculate Optimal Fill Time using the SOLIDCast GatingDesign Wizard.
4. For bottom-pour ladles, you can calculate a variable flowrate using the Ladle Calculation Utility, too.
![Page 170: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/170.jpg)
Using FLOWCast
FLOWCast assumes that metal flows inperpendicular to Fill Material surfaces. Therefore,you should avoid “plunging” Fill Material into thetop of a sprue:
Right Wrong
![Page 171: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/171.jpg)
Using FLOWCast
There are two ways to start FLOWCast.
Method 1: Use Mesh… Start FLOWCast
This loads FLOWCast. You then select settingsand start the flow simulation manually.
![Page 172: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/172.jpg)
This is the FLOWCast main screen. Youcan adjust the display from this screen.
To set the steps for saving data, click theFilling tab.
![Page 173: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/173.jpg)
This allows you to set the increment forsaving ALL data (temperature andvelocity) and also just temperature data,which creates a smaller output file.
![Page 174: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/174.jpg)
Here we’ve set the increment for savingtemperature data to 1%. This will allowus to create a video file later on using 100frames or pictures.
![Page 175: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/175.jpg)
FLOWCast allows you to select either aFULL CFD solution or a Quick solution.When the hourglass button is depressed,this indicates you’ve selected the Quicksolution.
![Page 176: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/176.jpg)
To start the flow simulation, click thedouble arrow.
![Page 177: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/177.jpg)
The Status tab shows data sets saved forFULL data, and is also where you go tocreate animation files of temperature,velocity and pressure after thesimulation is complete.
![Page 178: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/178.jpg)
The Anim tab shows sets of savedtemperature data, and is also where yougo to create movies showing temperaturewhen the simulation is complete.
![Page 179: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/179.jpg)
The Pathlines tab allows you to turn onor off the tracks of virtual particles whichare released into the incoming metal atevery 10% increment of fill.
![Page 180: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/180.jpg)
Using FLOWCast
Q: How do I use results of a FLOWCast simulationas the start of a SOLIDCast simulation?
If you’ve run FLOWCast using the Mesh… StartFLOWCast option, just start a simulation usingMesh… Start Simulation and pick SOLIDCast asthe Fill Algorithm:
![Page 181: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/181.jpg)
Using FLOWCast
If you want to run FLOWCast and then SOLIDCastautomatically, use Method 2:
First, select Mesh… StartSimulation
Then specify the FLOWCastAlgorithm (Full or Quick) youwant to use
![Page 182: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/182.jpg)
Ways to Visualize Flow Patterns withFLOWCast
1. Velocity Vectors
2. Trace Particle Paths
![Page 183: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/183.jpg)
Velocity Vectors are plotted onsectional planes cut through themodel. To set up plotting ofVelocity Vectors, we first need toselect Velocity as the item to plot.
![Page 184: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/184.jpg)
Next we select a view or rotate themodel to the desired view.
![Page 185: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/185.jpg)
We can turn off Perspective …
![Page 186: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/186.jpg)
… to get an Orthogonal view.
![Page 187: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/187.jpg)
From the Settings menu we canselect the color for the VelocityVectors…
![Page 188: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/188.jpg)
… the thickness of the vectors…
![Page 189: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/189.jpg)
… and the size of the vectorheads.
![Page 190: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/190.jpg)
To turn on vector plotting, weselect a Cutting Plane (in this casethe X-Z Plane) and ask the systemto Display Veloc Vectors on Plane.
![Page 191: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/191.jpg)
Velocity Vectors show thedirection of flow of metal at everypoint on the cutting plane…
![Page 192: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/192.jpg)
… showing flow streams, vorticesand areas of high and low velocity.
![Page 193: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/193.jpg)
![Page 194: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/194.jpg)
![Page 195: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/195.jpg)
Particle Tracks
Particle tracks shows the pathof simulated particles
released into the incomingstream at specific intervals.
![Page 196: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/196.jpg)
Particle tracks are turned on byselecting the Pathlines tab. Color,thickness and number of trackscan be controlled with theSettings menu.
![Page 197: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/197.jpg)
This shows paths of particlesreleased at the start of filling.
![Page 198: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/198.jpg)
At 20% full…
![Page 199: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/199.jpg)
At 50% full…
![Page 200: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/200.jpg)
And at 80% full. Particle trackscan also be included in movie(AVI) files.
![Page 201: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/201.jpg)
A Third Example of Using theRiser Design and Gating
Design Wizards:
Designing for multi-cavity production
![Page 202: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/202.jpg)
Using SOLIDCast and FLOWCastsoftware, we will develop a design forthe rigging and production of this 356
aluminum alloy casting.
The first step involves consideration ofthe casting geometry, without gates or
risers.
![Page 203: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/203.jpg)
Casting model as furnished bythe foundry.
![Page 204: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/204.jpg)
Casting model as furnished bythe foundry.
![Page 205: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/205.jpg)
Using the Riser Design Wizard inSOLIDCast as a starting point, we
analyze this shape to determine theModulus* of the casting. Modulus is apredictor of the order of solidification
of various parts of the casting, and canbe 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 isdefined as the ratio of Volume:Surface Area. SOLIDCast
uses a Thermal Modulus which is more accurate thantraditional V/SA analysis.
![Page 206: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/206.jpg)
Plot of Modulus values in thiscasting.
![Page 207: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/207.jpg)
Plot of Modulus values in thiscasting.
Point of maximumModulus. This is thelast point to freeze,and the best place toattach a riser.
![Page 208: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/208.jpg)
The Riser Design Wizard can analyzethe patterns of Modulus values within acasting and make recommendations asto how many risers are required, wherethey should be placed, and what size
they should be.
![Page 209: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/209.jpg)
Here’s the Riser Design Wizard’s starting screen.
![Page 210: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/210.jpg)
By analyzing patterns within thecasting, the Wizard tells us that threerisers would be the optimal design.
![Page 211: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/211.jpg)
Next, by using an “X-ray” view of thecasting, we can see where these high-modulus areas are in the casting. Intheory, each of these areas should be
fed by its own riser.
![Page 212: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/212.jpg)
Main feeding areaSecondaryfeeding areas
![Page 213: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/213.jpg)
The next series of views shows thelocation suggested by SOLIDCast as
the best attachment point for the mainriser, considering the point of highest
modulus within the casting.
![Page 214: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/214.jpg)
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![Page 219: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/219.jpg)
Now, the Riser Design Wizard is able torecommend riser sizes for each of
these areas. Riser size is determinedby consideration of Modulus (the
Modulus of the riser should be greaterthan the Modulus of the casting) andvolume (the volume of the riser mustbe sufficient to provide feed metal tocompensate for the contraction of the
alloy during liquid cooling andsolidification).
![Page 220: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/220.jpg)
Here, the required riser size is givenas 2” diameter X 5” high. The volumerequirement controls. This is for the
main riser for one casting.
![Page 221: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/221.jpg)
Assuming that we might feed twocastings with a common riser, we can
adjust riser dimensions to provideenough feed metal for two castings.
![Page 222: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/222.jpg)
Doing this, required riser size to feed(2) castings is 2.5” diameter X 6”
high.
![Page 223: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/223.jpg)
Now we can ask the system to size thesmaller, secondary risers, as follows:
![Page 224: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/224.jpg)
Riser 2 is given as 1.5” diameter
X 3” high.
![Page 225: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/225.jpg)
And Riser 3 requires the samedimensions, 1.5” diameter X 3” high.
![Page 226: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/226.jpg)
Next, the Gating Design Wizard cangive us a suggested Optimal Fill Time
and sizes for sprue, runners and gates.
![Page 227: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/227.jpg)
Calculating a Pour Weight for (4)castings per mold, and taking into
account the Critical Wall Thickness of0.217” in the casting, the Gating
Design Wizard suggests an OptimalFill Time of 8.7 seconds.
![Page 228: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/228.jpg)
Here we specify the gatingarrangement and a gating
ratio of 1:2:2
![Page 229: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/229.jpg)
The Wizard tells us we should have asprue that is .897” diameter (we’ve
assumed a round straight spruehere).
![Page 230: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/230.jpg)
And the runner size should be .632square inches.
![Page 231: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/231.jpg)
Using this information, we can create aninitial gating and riser design for
production of this casting in a 4-on mold.
![Page 232: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/232.jpg)
Initial Suggested Design forGates and Risers
![Page 233: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/233.jpg)
What happened to the secondary risers1 and 2?
In our initial design, we will test to seeif the temperature distribution due tofilling through the main riser will beenough to overcome the need forsecondary risers, by encouraging
directional solidification into the largeriser. If not, we’ll add them later… or
we could try chilling those areasinstead.
![Page 234: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/234.jpg)
The next step is to run a simulation ofthis casting, using the initial design.This will involve using FLOWCast tomodel the flow of the liquid into thecasting, and SOLIDCast to model
solidification and shrinkage formation.This will allow us to evaluate this
design and determine whether anyfurther modifications are necessary.
![Page 235: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/235.jpg)
FLOWCast is a flow simulation modulewhich models the filling of the gatingand mold cavity. FLOWCast models
progressive temperature and velocityof the liquid metal.
![Page 236: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/236.jpg)
The following series showsprogressive temperature of the liquid
metal during filling.
![Page 237: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/237.jpg)
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FLOWCast can also show flowpathlines, or particle trace lines. Thishelps to visualize the flow of the metaland determine whether any excessive
vortexing or turbulence may beoccurring. This can also be used to
predict the likely end location offoreign particles (oxides or dirt)entrained in the metal stream.
![Page 243: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/243.jpg)
Flow Pathlines
![Page 244: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/244.jpg)
FLOWCast can also show velocity of theliquid metal at any point in the liquid.
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FLOWCast can also show pressure ofthe liquid metal at any point in the liquid.
![Page 247: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/247.jpg)
![Page 248: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/248.jpg)
FLOWCast is used to visualize how thegating will function, and how the moldwill fill. Flow-related defects such as
misruns or cold shuts can beidentified. It also provides the most
realistic temperature distribution in thecasting and mold for a subsequent
solidification analysis.
In this case, the flow sequence looksgood. Now let’s progress on to
analysis of the solidification of thecasting.
![Page 249: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/249.jpg)
SOLIDCast is used to predict thecooling and solidification of thecasting after filling, as well as
formation of any shrinkage(macroporosity or microporosity).
![Page 250: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/250.jpg)
Here we see the predicted finaltemperature distribution in thecasting, at the end ofsolidification.
This shows a good temperature gradient fromthe far side of the casting back into the risers.
![Page 251: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/251.jpg)
This image shows the pattern ofsolidification in the castings.
This shows a good pattern of directionalsolidification out of the castings and into therisers.
![Page 252: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/252.jpg)
Prediction of macroporosity(shrinkage) in the castings.
X-Ray View
![Page 253: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/253.jpg)
Prediction of areas of microporosity(dispersed micro-shrinkage) in thecastings.
X-Ray View
![Page 254: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/254.jpg)
Conclusion
By using the gating and risers assuggested by the Gating and Riser
Design Wizards, we were able todesign the process for this casting
very rapidly. By using FLOWCast andSOLIDCast, we were able to verify
through simulation that this designshould produce a sound casting.
![Page 255: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/255.jpg)
Casting Analysis
737305 INSERT
9-April-2004
![Page 256: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/256.jpg)
Step 1:
Casting Model as Imported fromCAD File
![Page 257: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/257.jpg)
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![Page 260: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/260.jpg)
Step 2:
Analysis of Thermal Modulus
![Page 261: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/261.jpg)
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Step 3:
X-Ray View of Thermal Analysis
For Feeder Locations
As identified automatically by the SOLIDCastRiser Design Wizard.
![Page 267: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/267.jpg)
Feeder Location 1
Feeder Location 2
Feeder Location 3
Feeder Location 4
![Page 268: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/268.jpg)
Step 4:
Calculation of Required FeederSize at Each Location
(In this calculation, we have assumed nosleeves.)
This approach considers Modulus and VolumeRequirement for each Feeder.
![Page 269: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/269.jpg)
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Step 5:
Calculation of GatingComponents:
Sprue, Runners and Gates
![Page 274: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/274.jpg)
Calculation of Optimal Fill Time Specification of Gating Parameters
Calculation of Sprue Sizes Calculation of Runner and Gate Sizes
![Page 275: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/275.jpg)
Step 6:
Development of Initial RiggingDesign for Casting Production
![Page 276: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/276.jpg)
Design #1
![Page 277: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/277.jpg)
Filling Simulation: 10% Full
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Filling Simulation: 80% Full
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Filling Simulation: 100% Full
![Page 280: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/280.jpg)
Temperature Distribution at End of Solidification
![Page 281: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/281.jpg)
Progressive Solidification
![Page 282: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/282.jpg)
X-Ray View of Shrinkage (Macroporosity) Prediction
Small Area ofPredicted Shrinkage
![Page 283: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/283.jpg)
Step 6:
Design Iteration #2
![Page 284: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/284.jpg)
Design #2
Two smaller topfeeders
![Page 285: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/285.jpg)
Filling Simulation: 10% Full
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Filling Simulation: 80% Full
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Filling Simulation: 100% Full
![Page 288: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/288.jpg)
Temperature Distribution at End of Solidification
![Page 289: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/289.jpg)
Progressive Solidification
![Page 290: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/290.jpg)
X-Ray View of Shrinkage (Macroporosity) Prediction
No PredictedShrinkage in Casting
![Page 291: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/291.jpg)
Timing Data
CFD Flow Simulation: 111 Minutes
Solidification Simulation: 13 Minutes
![Page 292: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/292.jpg)
An Example in Cast Iron
The Iron Property Calculator
With Riser Design
![Page 293: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/293.jpg)
First, the STL file is loaded.
![Page 294: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/294.jpg)
This is what the shape looks like.
![Page 295: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/295.jpg)
I select a 4 CE gray iron asthe Casting Alloy. I haveadjusted the pourtemperature to about 70degrees below the 2550Ftemperature you gave me,because we are initiallygoing to simulate the ironalready in the mold and a70F temperature drop is atypical estimate for theloss from filling.
![Page 296: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/296.jpg)
I select silica sand as moldmaterial.
![Page 297: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/297.jpg)
And make sure thatInternal HT Coefficientsare not turned on, and theExternal HT Coefficient isset to about 1.5.
![Page 298: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/298.jpg)
Now we mesh the model with arelatively coarse mesh… 500,000Nodes with 3” of sand all around.
![Page 299: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/299.jpg)
And we start a simulation running.
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The simulation should run fairly quickly.
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When the simulation is done, we double-click on“Simulation” on the Project Tree, which displays theSimulation Status window. We close this window.
![Page 302: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/302.jpg)
Then we select Simulation… Riser DesignWizard. All we are doing at this point iscalculating the modulus of the casting.
![Page 303: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/303.jpg)
In the Riser Design Wizard, we select “Calculate andDisplay Casting Modulus” and press Next.
![Page 304: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/304.jpg)
Then we select “Plot Iso-Surface” and press Next.
![Page 305: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/305.jpg)
On this window we can see the maximum value ofmodulus, which is 1.215. This is the casting modulus.That’s all we need for the moment, so we cancel this plotand close the Riser Design Wizard.
![Page 306: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/306.jpg)
We also need the casting weight, so we select “Mesh”and “Weights” from the menu.
![Page 307: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/307.jpg)
And we see that the weight of the casting is about 812pounds.
![Page 308: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/308.jpg)
Next we go to the Tools menuand select “Iron PropertyCalculator”.
![Page 309: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/309.jpg)
Here I have assumed a carboncontent of 3.4%, silicon 1.8%and P of 0.02%. We fill in thecasting modulus as 1.215(calculated previously) and forTemperature in the Mold weenter 2480.
Pressing the “Calculate” button,we see that the Shrinkage Timeis 41.88% and the amount ofcontraction is 2.19%.
Next, we press the Riser Designbutton.
![Page 310: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/310.jpg)
This brings up thenew Iron CastingRiser Designwindow. We fill inthe weight of 812 lbs,set the amount ofmold dilation to 1%(for green sand),assume a side sandriser and set the H:Dratio to 1.5.
![Page 311: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/311.jpg)
Now, pressing“Calculate”, we seethe required sandriser size is about8.4D x 12.6H. Alsonote that the NeckModulus is .786.
![Page 312: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/312.jpg)
Here are thedimensions if wehave an InsulatingSleeve.
![Page 313: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/313.jpg)
And for anExothermic Sleeve.
![Page 314: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/314.jpg)
Closing the Iron Casting Riser Designwindow, we now go back to the Simulation…Riser Design Wizard function. Now that weknow the neck modulus, we want to see ifthere is a single feeding area or multiplefeeding areas in this casting, using the neckmodulus as a guide.
![Page 315: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/315.jpg)
In the Riser Design Wizard, again we select “Calculateand Display Casting Modulus” and press Next.
![Page 316: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/316.jpg)
Then we select “Plot Iso-Surface” and press Next.
![Page 317: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/317.jpg)
Now on the plot parameters, we enter the neck moduluswhich is 0.786 into the “Plot This Value” field. Then wepress OK to plot this value.
![Page 318: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/318.jpg)
This plot shows that there is a SINGLE FEEDING ZONEin this casting, based on the neck modulus. This meanswe should use a single riser on this casting.
![Page 319: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/319.jpg)
This is what a sand riser might look like, based on thedimensions as calculated with the Iron Casting RiserDesign program.
![Page 320: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/320.jpg)
Now we want to know what size sprue and gate to designfor this casting. We select Simulation… Gating DesignWizard, select Horizontal Gating, enter an estimatedpouring weight of 1200 lbs., section thickness of 3.2inches and press “Calc. Fill Time”. This gives us acalculated Optimal Fill Time of 53 seconds.
![Page 321: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/321.jpg)
Here we make some assumptionsabout sprue height and specify agating ratio of 4:8:3 (pressurized).
![Page 322: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/322.jpg)
The program tells us that the topsprue diameter should be about3.5” and the bottom diameterabout 2.1”.
![Page 323: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/323.jpg)
Now we design a gate. The bestconfiguration is to gate into the riser,and to keep a 1:5 ratio of H:W on thegate so that the gate freezes quicklyenough. The program calculates agate size of 0.5” x 5.3” for thiscondition.
![Page 324: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/324.jpg)
Adding this simple gating system to themodel, we end up with a system that lookslike this.
![Page 325: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/325.jpg)
What’s left? We might be able toreduce the size of the risers and still
produce a sound casting, thusimproving yield. This can be done by
testing a few smaller riser designs andrunning new simulations… or we coulduse the OPTICast module and have the
system automatically find the “best”riser design which produces a sound
casting while maximizing yield.
![Page 326: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/326.jpg)
How do we know thatoptimum process designs
are actually beingachieved?
![Page 327: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/327.jpg)
The highest quality casting at thelowest cost.
The most efficient way to produce acasting.
What do we mean by“OPTIMUM”?
![Page 328: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/328.jpg)
The current process…
![Page 329: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/329.jpg)
Foundry Engineer
InitialDesign
ProcessSimulation
System
Foundry Engineer
RevisedDesign
Simulation Results
DecideWhat toChange
Acceptable?
NotAcceptable?
Done
![Page 330: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/330.jpg)
A new paradigm…
![Page 331: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/331.jpg)
Foundry Engineer
InitialDesign
ProcessSimulation
System
RevisedDesign
Simulation Results
DecideWhat toChange
Acceptable?
NotAcceptable?
Done OptimizationEngine
![Page 332: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/332.jpg)
OptimizingEngine
Casting ProcessSimulator
Computer Operating System andHardware
The “Layered System” Approach
![Page 333: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/333.jpg)
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 engineer’s time
Provides a more thorough and repeatabledesign process.
![Page 334: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/334.jpg)
Steps Required for Optimization
• Design Variables
• Constraints
• An Objective Function
1) Develop an Initial Design.
2) Define three types of elements:
3) Launch the Optimization
![Page 335: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/335.jpg)
Design Variables
These are elements that are allowed to vary when thecomputer 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
![Page 336: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/336.jpg)
One Type of Design Variable – Geometric Feature Size
![Page 337: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/337.jpg)
Another Type of Design Variable: Initial Temperature
![Page 338: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/338.jpg)
Constraints
A constraint is some aspect of a design thatdetermines whether that design is acceptable or not.
Typical Constraints:
Macroporosity Level
Microporosity Level
Yield Percentage
Minimum Cooling Rate
Minimum Thermal Gradient
![Page 339: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/339.jpg)
The Objective Function
The Objective Function is the single result which youare trying to either maximize or minimize.
Typical Objective Functions:
Maximize Yield Percentage
Minimize Macroporosity Level
Minimize Microporosity Level
Maximize Cooling Rate
Maximize Directional Solidification
![Page 340: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/340.jpg)
The Optimization Process
The Optimization Engine varies each Design Variablewithin the Design Space to create a series of process
models.
Each design is evaluated as to whether it violates anyConstraint.
Each design is then evaluated to determine if theObjective Function has been achieved, through the
use of convergence criteria.
![Page 341: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/341.jpg)
Modify the 3DSimulation
Model
Run a Simulationwith
ExamineResults
WereConstraints
violated?
Was anoptimum
value of theObjectiveFunction
achieved?
Decide on newvalues for Design
Variables
DONE
Yes/No
No/Yes
How OPTICast Works
![Page 342: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/342.jpg)
The Optimization Engine evaluates Response Surfaces.
![Page 343: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/343.jpg)
Requirements of the Modeling System forApplication of Optimization
Must be able to automatically modify geometry
Must be able to handle shape interference as shapesare modified
Must be able to automatically remesh each design
Must be able to process multiple simulations asquickly as possible
![Page 344: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/344.jpg)
Optimization allows us to take aninitial process design and, from that
design, find the OPTIMUM designwhich will result in maximum part
quality and minimum part cost.
![Page 345: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/345.jpg)
Example: Automotivecasting – Current Design
![Page 346: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/346.jpg)
Current RiserDimensions:
92 mm Dia. at P/L
175 mm Overall Height
![Page 347: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/347.jpg)
Simulation of current risershows adequate size and mass
to feed the casting properly.
![Page 348: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/348.jpg)
Sectional view showingsimulation of currentriser feeding
![Page 349: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/349.jpg)
“X-ray” view showingsimulation of currentriser feeding
![Page 350: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/350.jpg)
Question:
Can the weight of the riser bereduced, and yet still provide
adequate feeding to thecasting?
We can answer this questionusing mathematical
optimization.
![Page 351: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/351.jpg)
The OPTICast™ systemcombines the SOLIDCast™casting simulation packagefrom Finite Solutions, Inc.
with HyperOpt® Optimizationfrom Altair Engineering.
![Page 352: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/352.jpg)
In order to performoptimization on this riserdesign, we need to define
three parameters:
• Design Variables
• Constraints
• Objective Function
![Page 353: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/353.jpg)
Design Variables are anyaspects of the design that we
will allow the optimizer tovary during the optimization
run.
![Page 354: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/354.jpg)
Here we have selected the riseras a Design Variable. ItsHeight and Diameter will beallowed to vary independently.
![Page 355: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/355.jpg)
A Constraint is an outputwhich determines whether a
design is acceptable.
Here we set Casting Porosityas a constraint. Porosity is
measured by considering theminimum local material
density in the casting. Theconstraint value is set to 1.0,which indicates no casting
porosity allowed.
![Page 356: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/356.jpg)
The Objective Function is asimulation output which
measures the end result weare trying to achieve.
![Page 357: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/357.jpg)
For purposes of this optimization, wedefine a yield number such that
Yield =
The Objective Function is themaximization of this number, which
results in minimum riser weight.
Casting Weight
Casting + Riser Weight
![Page 358: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/358.jpg)
The Optimization Process
The Optimization Engine varies each Design Variablewithin the Design Space to create a series of process
models.
Each design is evaluated as to whether it violates anyConstraint.
Each design is then evaluated to determine if theObjective Function has been achieved, through the
use of convergence criteria.
![Page 359: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/359.jpg)
Modify the 3DSimulation
Model
Run a Simulationwith
ExamineResults
WereConstraints
violated?
Was anoptimum
value of theObjectiveFunction
achieved?
Decide on newvalues for Design
Variables
DONE
Yes/No
No/Yes
How OPTICast Works
![Page 360: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/360.jpg)
Optimization Results
The riser design optimization wascomplete after 26 simulations. These
were run completely automatically.
Total processing time was 2 hr. 56 min.on a 1.0 GHz PC.
![Page 361: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/361.jpg)
This chart shows the progressive value of the Yield functionover 26 simulations. Its value started at 0.60 and ended at 0.72.
![Page 362: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/362.jpg)
This chart shows simulated porosity in the casting. A value of1.0 represents a completely sound casting. Final value of 0.9995
is within allowable limits.
![Page 363: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/363.jpg)
A plot of the vertical scale of the riser. The final riser design is13.1% taller than the current riser.
![Page 364: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/364.jpg)
A plot of the horizontal scale (diameter) of the riser. The finalriser design is smaller (72%) in diameter than the current riser.
![Page 365: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/365.jpg)
Comparison of current riser vs.optimized riser design
92 mm Dia. X 175mm Height.
66 mm Dia. X 198mm Height.
![Page 366: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/366.jpg)
Simulation of the optimizedriser design shows adequate
size and mass to feed thecasting properly.
![Page 367: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/367.jpg)
Sectional view showingsimulation of optimizedriser feeding
![Page 368: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/368.jpg)
“X-ray” view showingsimulation of optimizedriser feeding
![Page 369: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/369.jpg)
Optimized riser shownwith gating
![Page 370: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/370.jpg)
Weight Reduction
Current Riser Weight: 16.03 lbs.
Optimized Riser Weight: 9.39 lbs.
Weight Reduction/Riser: 6.64 lbs.
Weight Reduction/Mold (8-on): 53.1 lbs.
![Page 371: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/371.jpg)
Conclusion of Optimization:
• Pour weight per mold can be reduced by53.1 pounds through redesign of the riser byoptimization
• At current production volumes, this results ina saving of more than $US 100,000 per year(1800 tons of metal saved annually)
• Annual Energy Savings: 1,980,000 KWH
![Page 372: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/372.jpg)
Process Design Optimization for:
Stainless Steel Investment Casting
Pour Temperature: 2925ºF
Shell Preheat: 1800ºF
Shell Thickness: 0.5”
Alloy: CF8M
![Page 373: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/373.jpg)
![Page 374: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/374.jpg)
![Page 375: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/375.jpg)
In this case, we start with Design Iteration#7, which produced a shrink-free casting.
![Page 376: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/376.jpg)
Wedge shapes, approx. 1.5” wide
This designused two smallwedge shapesunder the gatesto help feedmetal into theheavy section ofthe casting.
![Page 377: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/377.jpg)
Here’s the gatedesign that willbe optimized byusing OPTICast.
![Page 378: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/378.jpg)
The first step is to select Design Variables.These are features of the gating that are
allowed to vary in size.
![Page 379: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/379.jpg)
Here we’ve selectedthe horizontal feederbar as DesignVariable #1.
![Page 380: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/380.jpg)
The pour cup isselected as DesignVariable #2.
We’re specifiedthat ONLY thehorizontaldimensions of thepour cup canvary; its heightstays constant.
![Page 381: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/381.jpg)
The gate is selectedas Design Variable#3.
The gate’s heightis held constant,but its width isallowed to vary.
![Page 382: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/382.jpg)
The other gate is“linked” to thefirst gate, whichmeans that thetwo gates willalways be thesame shape.
![Page 383: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/383.jpg)
Now we need to apply a Constraint. This isan OUTPUT VALUE from each simulationwhich determines whether the results are
acceptable or not.
In this case, our constraint is that thecasting must be “free of shrinkage”. Anydesign which results in shrinkage in the
casting will be discarded.
![Page 384: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/384.jpg)
We measureshrinkage asMaterialDensity. Avalue of 1means aperfectly soundcasting, so weset theConstraintValue to 1.
![Page 385: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/385.jpg)
Finally, we select an Objective Function.This is an OUTPUT VALUE that we aretrying to either maximize of minimize.
In this case, our objective function will be to“Maximize the Yield”. This means that themaximum yield (i.e., the minimum amountof poured metal weight) which produces a
shrink-free casting will be found.
![Page 386: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/386.jpg)
This is done just byselecting YieldMaximization from a listof Objective Functions.
![Page 387: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/387.jpg)
At this point, we start the optimizationrunning. This is a TOTALLY AUTOMATIC
process. OPTICast will run a series ofsimulations, varying the gate design untilthe yield is maximized and the casting is
shrink-free.
This process can be illustrated as follows:
![Page 388: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/388.jpg)
Modify the 3DComputer
Model
Run a Simulation
ExtractResults
WereConstraints
violated?
Was anoptimum
value of theObjectiveFunction
achieved?
Decide on newvalues for Design
Variables
DONE
Yes/No
No/Yes
The Optimization Process
![Page 389: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/389.jpg)
In effect, the computer is redesigning thisgating system ON ITS OWN, using the
rules and guidelines that we set up.
Now let’s look at the Results…
![Page 390: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/390.jpg)
Here is the Yield foreach of 50simulation runs.
The yield increasedfrom 38% to 53%.
![Page 391: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/391.jpg)
This chart showscasting soundnessfor each of 50simulation runs.
A value of 1.0means a soundcasting (no shrink).
![Page 392: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/392.jpg)
This shows thehorizontal scalefactor for the feeder.
The optimizedfeeder is 82% of itsoriginal size(horizontally).
![Page 393: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/393.jpg)
This chart showsthe vertical scalefactor for the feeder.
The optimizedfeeder is 83% of itsoriginal size(vertically).
![Page 394: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/394.jpg)
This shows thehorizontal scalefactor for the pourcup.
The optimized pourcup is 42% of itsoriginal size(horizontally).
![Page 395: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/395.jpg)
And, finally,thischart shows thehorizontal scalefactor for the gates.
The optimized gatesare 120% of theiroriginal size(horizontally).
![Page 396: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/396.jpg)
So, how does the optimized designcompare with the original gating design?
![Page 397: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/397.jpg)
Original Gating Optimized Gating
SolidificationPattern
Hot Spots No HotSpots
![Page 398: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/398.jpg)
Original Gating Optimized Gating
ShrinkagePrediction
Shrinkage inCasting
NoShrinkage in
Casting
![Page 399: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/399.jpg)
Original Gating Optimized Gating
123 Lb. Pour Weight 88.3 Lb. Pour Weight
![Page 400: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/400.jpg)
Final Results
1. Pour weight reduced 34.7 Lbs.per casting
2. Shrinkage eliminated fromcasting
3. Annual savings: $17,000
4. Energy savings: 7,000 KWH/yr
![Page 401: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/401.jpg)
Utilities Menu
The Utilities Menu gives access to a wide variety of functions.
![Page 402: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/402.jpg)
Convert ASCII STL to Binary
Allows you to convert an ASCII STL file to aBinary STL file so that it can be loaded into
SOLIDCast as a model shape.
![Page 403: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/403.jpg)
Create Shell Around STL Shape
This program accepts an STL file as input, andcreates a new STL file as output which
represents a shell of a constant thickness aroundthe first STL file. This shell shape can then bebrought into the SOLIDCast model as a model
shape.
![Page 404: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/404.jpg)
Custom Formula
Allows you to create a customized formula forcalculation and plotting from SOLIDCast results. Forexample, 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 CustomFormula, and plotted using Custom-High.
![Page 405: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/405.jpg)
Data Capture (Temperature)
Allows you to capture time/temperature data from anunlimited number of points within a model.
![Page 406: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/406.jpg)
Early Fill Tilt Pour
This utility allows most of the metal in a tilt pourFLOWCast simulation to enter the mold at a givenpercent 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 metalwill have entered the mold during the first 45 degrees
of tilting.
![Page 407: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/407.jpg)
Filter Shape
This utility helps you to create an STL file consistingof a rectangular block with cylindrical holes. This
object, when added to a model and given ceramicthermal properties, can be used to simulate a filter.
![Page 408: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/408.jpg)
HTC Calculator
This utility helps to calculate the appropriate HeatTransfer Coefficients to use for various situations.
Calculations are included for:
• Air and water cooling channels
•Natural and forced convection
•Radiation
•Mold coatings
![Page 409: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/409.jpg)
Iron Property Calculator
Allows you to calculate % contraction/expansion andCFS point for cast iron, based on the German Iron
Society VDG Nomograms and the charts developedby Karsay. This utility also performs risering
calculations for cast irons, as demonstrated in thefollowing slides.
![Page 410: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/410.jpg)
Design of risers for Grey Iron andDuctile Iron castings involves one
primary consideration above all else:
Control of Expansion Pressure
This means allowing riser necks toremain open long enough to feed
liquid shrinkage, but ensuring thatthey freeze in time to pressurize thecasting during expansion and avoid
formation of shrinkage porosity.
![Page 411: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/411.jpg)
The solidification of iron castings(ductile, or nodular, iron and gray
iron) is unique among cast metals,due to the precipitation of graphite asthe iron solidifies. The graphite takesvarious forms depending on the typeof iron. For example, in ductile iron
(nodular iron), the graphite isprimarily spheroidal, which gives theiron its characteristic ductility since
the spheroids tend to reducelocalized stresses under load.
![Page 412: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/412.jpg)
![Page 413: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/413.jpg)
While in gray iron, the graphite tendsto be in the shape of flakes, which
results in gray iron’s greatcompressive stress but relatively low
tensile stress.
![Page 414: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/414.jpg)
![Page 415: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/415.jpg)
And in compacted graphite iron, thestructure and properties tend to be
somewhat intermediate.
![Page 416: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/416.jpg)
![Page 417: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/417.jpg)
The precipitation of graphite duringsolidification causes some expansion tooccur, 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 allliquids when cooled. During solidification,
the austenitic iron also contracts as do mostmetals upon solidification. However, the
precipitating graphite causes an expansionpressure which can be used to our
advantage if the feeding system is properlydesigned.
![Page 418: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/418.jpg)
No matter which type of cast iron weare pouring, the secret of good
design is to provide a feeding systemto compensate for the liquidshrinkage and then allow the
expansion (due to carbonprecipitation) to provide enough
pressure to produce a sound casting.
There are some differences inexpansion pressure between ductileiron and grey iron as shown in the
following chart:
![Page 419: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/419.jpg)
![Page 420: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/420.jpg)
Regardless of the type of iron castingwe are designing, there are a set of
basic procedures that can befollowed which will help us to ensure
high-quality, sound iron castings,using the SOLIDCast Simulation
System. These procedures will helpto minimize the number of sample
castings required, reduce lead timesto get into production, and result in
consistent-quality castings which willmake our customers happy and our
foundry more profitable.
![Page 421: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/421.jpg)
Step 1
To begin analyzing a casting inSOLIDCast for the purpose of riser
design, we initially run a simulation ofjust the casting, surrounded by mold
material, without gates or risers.
![Page 422: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/422.jpg)
Step 2
We then run the SOLIDCast RiserDesign Wizard and select "Calculate
and Display Casting Modulus" to findout the maximum modulus of the
casting.
![Page 423: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/423.jpg)
Step 3
We next run the SOLIDCast Cast IronProperty Calculator program to
calculate the Shrinkage Time (ST) andnet Percent Expansion (+) or
Contraction (-) of the iron based onchemistry, modulus and temperature
in the mold. This is based on theVDG Nomograms and Karsay charts
for iron properties.
![Page 424: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/424.jpg)
Step 4
This gives us the net expansion ofthe iron considering only the metal,
without taking into account thedilation of the mold. For actualfeeding requirement, we must
estimate mold dilation which mightvary from less than 0.5% for
chemically-bonded molds to morethan 2% for loose green sand molds.
![Page 425: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/425.jpg)
Step 5
Rule: Recommended practice wouldbe to use a "hot" riser, i.e., to gate
into the riser if using a side riser sothat 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, wewould typically recommend a sleeve(either exothermic or insulating) to
retain the heat.
![Page 426: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/426.jpg)
Step 6
The proportion of liquid metal that can besupplied by a riser can be estimated by
knowing its condition. For example, a hotside riser can typically provide about 20% ofits metal for feeding, while a typical cold riser
might provide around 14% of its metal. Asleeved riser can provide anywhere from 33%
to 35% depending on its condition.Exothermic mini-risers have been known toprovide up to 70% of their metal for feeding.
![Page 427: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/427.jpg)
Step 7
The formula relating the available volume ofmetal in a riser to the volume of the casting
can be expressed as:
Vf = Vc * Sx
(Where Vf = Riser Volume, Vc = Casting Volume, S = FeedingRequirement (including Mold Dilation), and x = Proportion of Liquid
Metal Removed from Riser)
and from this the diameter of the riser can becalculated if an assumption of riser
Height:Diameter is made.
______
![Page 428: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/428.jpg)
Step 8
The riser neck should be sized so that its modulusguarantees that it will freeze at the point that the liquidshrinkage is done and any subsequent expansion will
be controlled and contained within the casting toprevent shrinkage porosity formation. This can be
accomplished by using the following formula:
Mn = ST/100 * Mc
Where Mn = Modulus of the Neck, ST = ShrinkageTime, and Mc = Modulus of the Casting.
![Page 429: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/429.jpg)
Step 9
Also, in order for the riser to provide sufficient liquidmelt during the shrinkage period, its modulus shouldbe 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 feedingrequirement but it does not satisfy this modulusrequirement, its size must be increased to satisfy thismodulus requirement.
![Page 430: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/430.jpg)
Step 10
If the riser is close enough to the casting sothat mold heatup between the casting and
riser can be taken into account, the requiredmodulus 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 risershould be less than the minimum dimension
of the riser neck.
![Page 431: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/431.jpg)
Riser Neck
![Page 432: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/432.jpg)
![Page 433: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/433.jpg)
![Page 434: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/434.jpg)
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 bevisualized by plotting the neck modulus, alsocalled the Transfer Modulus. If more than one
riser is used for a single feeding zone, inalmost all cases only one of the risers will
pipe and the other riser(s) will not pipe but willcreate a thermal hot spot underneath at which
some shrinkage porosity will be likely toappear.
![Page 435: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/435.jpg)
Two risers, only onehas piped.
![Page 436: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/436.jpg)
In every case, eachcasting has tworisers and only onehas piped.
![Page 437: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/437.jpg)
Two risers, onecasting.
![Page 438: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/438.jpg)
This riser piped.
This riser piped.
![Page 439: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/439.jpg)
Step 12
SOLIDCast uses the THERMAL MODULUS tocalculate the location and extent of feedingzones within the casting. This is superior tothe traditional measure of Volume:SurfaceArea Ratio, as it is able to take into accountheat saturation of mold and core pockets aswell as heat extraction by chills and, ifdesired, temperature distribution due to filling.
![Page 440: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/440.jpg)
Step 13
The SOLIDCast Cast Iron Riser DesignProgram assumes that side risers arecylindrical with a hemispherical bottom, whiletop risers are cylindrical in shape.
Rule: The tops of the risers should be abovethe highest point of the casting for gray andductile iron casting, by at least the minimumsection thickness.
![Page 441: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/441.jpg)
![Page 442: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/442.jpg)
Step 14
Gating should be designed to freeze relativelyquickly after the liquid metal has filled themold cavity. In general, this means that thegate attachment to the casting should have a5:1 ratio of width to height to ensure relativelyquick freezing so that expansion pressure canbe contained. Remember, Control ofExpansion Pressure is our ultimate goal infeeding cast iron.
![Page 443: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/443.jpg)
“A”
![Page 444: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/444.jpg)
t = √A/5
![Page 445: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/445.jpg)
t = √A/3
![Page 446: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/446.jpg)
All of these calculations can be performedquickly and easily in
As an example, consider the task of designinga feeding system for the following ductile iron
casting.
![Page 447: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/447.jpg)
This is the basic casting shape as importedfrom a CAD system in SOLIDCast.
![Page 448: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/448.jpg)
Ductile Iron is selected asthe Casting Material fromthe SOLIDCast database.
![Page 449: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/449.jpg)
The casting is meshed withno risers or gates, so that a“thermal” simulation can berun for calculation of theModulus of the casting.
![Page 450: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/450.jpg)
Once the thermal simulationis complete, the SOLIDCastRiser Design Wizard isselected…
![Page 451: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/451.jpg)
… and the user instructs theWizard to calculate anddisplay the CastingModulus.
![Page 452: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/452.jpg)
The Iso-Surface Plot isselected…
![Page 453: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/453.jpg)
… and from the Iso-SurfacePlot Menu, we can read thatthe maximum Modulus ofthis casting is about 0.469in. At this point, this is allthe information we needfrom the Wizard, so we canjust press Cancel to avoidmaking the plot at this time.
![Page 454: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/454.jpg)
Another item of informationwe’ll need is the weight ofthe casting. This can beeasily obtained by selectingMesh… Weights from themain menu. Here we cansee that the casting weighs18.953 lb.
![Page 455: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/455.jpg)
Now we are ready to calculate the propertiesof the iron, and the required riser size.
![Page 456: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/456.jpg)
From the main menu, weselect Tools… Iron PropertyCalculator.
![Page 457: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/457.jpg)
Here we enter theCarbon, Silicon andPhosphorus contentof the iron.
Here we enter thecasting Modulus aspreviously calculatedby the Wizard.
And here we enter anestimate of thetemperature of themetal in the mold.
Clicking the Calculate Iron Properties button causes the system todisplay the Shrinkage Time (ST) in terms of % Solid, and the netamount of Expansion (+) or Contraction (-) which occurs up to thatShrinkage Time. This is the quality of the iron without consideringmold dilation.
![Page 458: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/458.jpg)
Now that we have the properties of the ironcalculated, we can design a riser for this
casting.
![Page 459: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/459.jpg)
First, we enter thecasting weight aspreviously calculatedby the system in theMesh menu.
![Page 460: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/460.jpg)
Next, we select theexpected amount ofmold dilation. This canbe anywhere from lessthan 0.5% for a veryrigid mold to more than2% for a loose greensand mold. Herewe’ve selected 1% fora well-made sandmold.
![Page 461: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/461.jpg)
The next item to selectis sleeve type. Youcan select either asand riser (no sleeve),an insulating riser,exothermic orexothermic mini-riser.You can also selectwhether the casting isgated through the riser.The proportion of liquidmetal removed fromthe riser isautomatically adjusted.
![Page 462: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/462.jpg)
Next we select the ratioof Height to Diameterthat we want to use forthe riser design.
![Page 463: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/463.jpg)
Finally, we have theoption to select either aTop or Side Riser.Here we have selecteda Side Riser.
![Page 464: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/464.jpg)
Now, pressing the Calculatebutton will display the requiredriser and neck size, as well asthe Modulus of the neck andthe riser. Note that the NeckModulus is also referred to asthe Transfer Modulus and canbe used to indicate how manyfeeding zones (and now manyrequired risers) there are forthis casting.
![Page 465: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/465.jpg)
Notice that by selecting theShort Neck option andrepressing the Calculatebutton, we can calculate aneck size for a riser which isvery close to the casting(closer than the minimumdimension of the neck).
![Page 466: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/466.jpg)
Now by plotting the Transfer Modulus in an X-RayView (Iso-Surface Plot) we can see that the entirecasting is one feeding zone, so only one riser isrequired for this casting.
![Page 467: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/467.jpg)
Another image of the Transfer Modulus, usingCastPic plotting, also shows one zone which meansone riser is required for this casting.
![Page 468: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/468.jpg)
A more traditional Modulus calculation usingVolume/Surface Area Ratio would have indicated twoseparate feeding areas, one in the central hub andone around the outer rim as shown here. Why isthere a difference?
![Page 469: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/469.jpg)
This cross-sectional view through the casting and mold showstemperature. You can see that the mold material becomes saturatedwith heat in the “pocket” areas between the inner hub and the outer rim,which keeps the thinner sections hot. This effect would not be capturedby performing the old-fashioned Volume/Surface Area Moduluscalculations, but is automatically taken into account when performingthe Thermal Modulus function within SOLIDCast, because thermaleffects in the mold are simulated.
Heat Saturation
![Page 470: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/470.jpg)
Now that we have the riser and neck dimensioned, we also need todimension the sprue, runner and gate, as well as estimate a fill time.The SOLIDCast Gating Wizard calculates an Optimal Fill Time of about13 seconds for this casting (assuming a single casting).
![Page 471: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/471.jpg)
And by describing the geometry of our proposedgating system…
![Page 472: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/472.jpg)
The Wizard calculates for us a sprue diameter of about 0.575 in.
![Page 473: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/473.jpg)
And an inlet gate of about 0.23 in. x 1.13 in., which shouldensure that the gate freezes quickly for control of expansionpressure.
![Page 474: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/474.jpg)
Now we can use all of the calculateddimensions to create a simple system for
gating and feeding this casting, which wouldappear as follows:
![Page 475: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/475.jpg)
The complete model: Casting, Neck, Riser,Gate and Sprue
![Page 476: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/476.jpg)
We use the results of the Cast Iron CalculationUtility Program to adjust the shrinkage curveparameters for the exact conditions of thisiron chemistry, temperature and modulus
value.
![Page 477: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/477.jpg)
Shrinkage Time of 63%, amountof shrinkage = -1.1% minus MoldDilation of 1% for a total shrinkageof -2.1%.
Add expansion of approximately0.5% per 10% solidification.
Set CFS Pointapprox. 5% to theright of the ST Point
![Page 478: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/478.jpg)
Using FLOWCast, we first perform a fillingsimulation of the casting, pouring metal downthe sprue, through the gate and riser and into
the casting cavity.
![Page 479: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/479.jpg)
![Page 480: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/480.jpg)
![Page 481: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/481.jpg)
![Page 482: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/482.jpg)
![Page 483: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/483.jpg)
Finally, we use SOLIDCast to perform asimulation of the solidification of the castingand to predict the soundness of the final part.
![Page 484: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/484.jpg)
Progressive Solidification
![Page 485: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/485.jpg)
Shrinkage Prediction
![Page 486: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/486.jpg)
Shrinkage Prediction: X-Ray View
![Page 487: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/487.jpg)
The Final Result
A sound casting, correctly designed using theSOLIDCast Riser and Gating Design tools, and
verified using SOLIDCast and FLOWCastsimulation.
www.finitesolutions.com
![Page 488: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/488.jpg)
Ladle Calculations
Allows you to calculate capacities, flow rates and filltimes from a given ladle. This utility also interfaces
to FLOWCast and allows fill simulation using variableflow rates from a ladle.
![Page 489: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/489.jpg)
Mask Riser Density
Removes Material Density data from Riser Materialareas so that you can see Material Density
indications ONLY within the casting.
![Page 490: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/490.jpg)
Plot SOLIDCast Fill Times
Allows you to plot fill times as calculated using theSOLIDCast (not FLOWCast) fill algorithm.
![Page 491: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/491.jpg)
Project Viewer
Allows you to select any model, mesh or simulationin a project and display summary information aboutthat item. For example, you can see exactly how a
model was meshed for simulation, how many shapesare in a model, how long a SOLIDCast simulation
took to run, and numerous other items of data.
![Page 492: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/492.jpg)
QuickPlot
Lets you change the plot display quickly and easily. You canchange the view, resolution and display method. You can also
re-plot very quickly, to create a sort of animation.
![Page 493: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/493.jpg)
Reduce STL File Size
This utility can be used to reduce the number oftriangles, and thus the file size, of an STL file for
easier loading and display in SOLIDCast.
![Page 494: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/494.jpg)
Reset Simulation Stop Point
This utility is used to change the end point of a simulation inSOLIDCast. For example, you can initially run a simulation untilthe casting is solid, and later use the utility to change the end
point when all metal is solid, or when the casting drops below aminimum temperature.
![Page 495: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/495.jpg)
Riser STL Shape
This utility is used to create an STL file for a riser ofgiven size and shape. The STL file can then be
loaded into an existing model in SOLIDCast.
![Page 496: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/496.jpg)
Scale Model Size
This utility can be used to scale the size of aSOLIDCast model up or down (larger or smaller) by a
given scale factor.
![Page 497: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/497.jpg)
Simulation Image Control
Allows you to adjust the view shown as a simulationruns. You can change the angle of the display, the
resolution of the picture and how the solidifyingnodes are displayed.
![Page 498: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/498.jpg)
Simulation Parameters
This utility is used to set several simulation parametersthat 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.
![Page 499: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/499.jpg)
SOLIDCast Settings System Info
This utility creates a display and a text file whichgives System Information about your computer andyour installation of SOLIDCast. This can be helpful
to Finite Solutions in diagnosing problems oranswering specific questions.
![Page 500: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/500.jpg)
Solidification Time Gradient Calc
This utility calculates and places solidification timegradient calculations from a simulation into the
Custom function so that they can be plotted. TheSolidification Time Gradient has shown promise as apredictor of areas in a casting prone to hot tearing.
![Page 501: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/501.jpg)
Split Files for Emailing
This utility is used to split large files into pieces sothat they can be emailed (or placed onto media) andis also used to recombine the pieces. Many emailsystems 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 UtilityProgram allows you to split these large files into
pieces which can be emailed to another person andthen recombined on the other end.
![Page 502: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/502.jpg)
STL From Model
This utility allows you to create a single STL file of aSOLIDCast model, no matter how many shapes were
used to build the model.
![Page 503: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/503.jpg)
STL Slice
This utility is used to create a 2D slice at a givenpoint through a binary STL file. The slice can be inthe XY, XZ or YZ orthogonal planes. The output 2Ddata can be either DXF format, or in AFSCad format.This is often useful for establishing exact dimensions
or locations of features on STL shapes.
![Page 504: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/504.jpg)
STL of Intersecting Cylinders
This is a special-purpose utility which creates an STLfile representing an intersection of two cylinders with
a fillet radius around the intersection, like this:
![Page 505: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/505.jpg)
Two Stage Pour
This utility is used to set up a file that can be used byFLOWCast for a two stage pour process. For
example, you could do the first 90% of filling from thesprue, pause for a number of seconds, then finishfilling by pouring hot metal into the top of a riser.
![Page 506: Training Overview SolidCast](https://reader031.vdocuments.site/reader031/viewer/2022012314/547ec883b4af9f4d688b459b/html5/thumbnails/506.jpg)
For More Information:
Contact
Dave Schmidt: [email protected]
262 644 0785
Or
Larry Smiley: [email protected]
513 737 7300