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ProCAST General Presentation
Shortening the product part development time Overall process improvement Reducing product cost Casting design optimisation Copyright © ESI Group, 2007 All rights reserved Outline • • • Introduction Typical Casting Defects Prediction Case Study – Al HPDC – Complete HPDC Process Simulation (cycling, shot piston, filling, solidification, stress, APM, Value Chain) - NADCA case • Case Study – Al HPDC – Improper mould filling in a multi-cavity steel die – Gas porosity problem • Case Study – Al HPDC – Improper mould filling in a multi-cavity steel die • Case Study – Steel Investment Casting – Gas and shrinkage porosity were observed in the initial design of the cast freight trailer component • Case Study – Steel Sand Casting – Primary & secondary shrink porosity in critical areas • Case Study – Steel Sand Casting – Improving yield by reducing pouring weight – Reducing machining cost ã Conclusion Copyright â ESI Group, 2007 All rights reserved Statement ProCAST is the leading FEM foundry simulation software, which provides coupled thermal-flow-stress analysis, along with unique metallurgical capabilities, for all casting processes and castable alloys • Proven Success of ProCAST 2005 Helps ESI Group Pick Up 2006 Frost & Sullivan European Technology Leadership of the Year Award Copyright © ESI Group, 2007 All rights reserved Modular Program Courtesy of ACTECH GmBH, Germany Al Sand Casting Courtesy of FOMET SpA, Italy Al Tilt Gravity Die Casting Courtesy of Kovolis Hedvikov Czech Republic Al High Pressure Die Casting Ni NGV Investment Casting Courtesy of MAN, Germany Cast Iron Sand Casting Courtesy of CMS, Turkey Al Low Pressure Die Casting Al Direct Chill Casting Copyright © ESI Group, 2007 All rights reserved ProCAST In Action Copyright © ESI Group, 2007 All rights reserved Geometry & Meshing • Utilises the Finite Element Method (FEM) – • Most accurate geometry description and analytic procedure Easy to import geometry from all CAD systems – Accepts: - One of the following CAD file format: • • • • • • • • – Acis Cadds Catia Pro-Engineer SolidEdge SolidWorks Unigraphics VDA Or one of the standard exchanges CAD file format: • • • – – – – Native (.sat) file Native (.pd) file Native V4 (.model, dlv, exp) or V5 (.catpart) file Native (.prt) file Native (.par) file Native (.sldprt) file Native (.prt) file Native (.vda) file Parasolids (.x_t, xmt_txt) file Neutral IGES (.igs) file with trimmed surfaces Neutral STEP (.step) file Direct FEM mesh import and export: I-DEAS, PATRAN, ANSYS, ARIES, ANVIL Coincident or non-coincident meshes Automatic 3-D mesh generation Export to other CAE packages • User Friendly menu driven interface • Platform flexibility – Windows, Linux – 32 and 64 bits Copyright © ESI Group, 2007 All rights reserved Material Properties AlSi5% / AlSi12.6 Al-Si 12.6% solid Al-Si 5% liquid solid Copyright © ESI Group, 2007 All rights reserved liquid Material Properties Complex phase diagrams ? A thermodynamic database is necessary ! Copyright © ESI Group, 2007 All rights reserved Material Properties Database • Standard Materials Included with Procast – 116 Metals and Alloys – 20 Other Materials (Sand, Refractory, Foam, Air, Water) • Thermodynamic Material Databases Available – Alloy families: Al, Fe, Mg, Ni, Cu and Ti – Thermo Physical properties predicted for the actual chemistry of your specific or proprietary alloy Copyright © ESI Group, 2007 All rights reserved Material Properties Thermodynamic Material Databases Thermo-physical data automatically set up from the chemical composition (Al, Cu, Fe, Ni, Ti, Mg based) Calculationthermodynamic solver Set up the chemical composition Run the of the solidification path Copyright © ESI Group, 2007 All rights reserved Conclusion • Selected customers in investment casting, mainly in the aerospace industry: Alstom, PCC Airfoils, PCC Structural, Howmet, Snecma, Rolls Royce, EMA, Doncasters, Microfusione Stellite, Centro Sviluppo Materiali, Microcast, Microsteel, Precicast, AIDC, Bet Semesh, Stryker Howmedica, MFL, GE, Pratt-Wittney, Mitsubishi, Ishikawajima Precision Casting, Starmet, Cercast, SALUT, Harbin Donkan Engine, Shenyang Liming Aero-Engine Group, Xi'an Aero Engine company… Copyright © ESI Group, 2007 All rights reserved Case Study - Steel Sand Casting First iteration: Initial design modification of back shroud section (top view) This concession allowed elimination of five top risers (bottom view) Copyright © ESI Group, 2007 All rights reserved Case Study - Steel Sand Casting Exploded view of mould assembly Copyright © ESI Group, 2007 All rights reserved Case Study - Steel Sand Casting Arrow shows shrinkage location on front shroud Copyright © ESI Group, 2007 All rights reserved Case Study - Steel Sand Casting Second iteration: Chill size was increased Riser diameter was increased Copyright © ESI Group, 2007 All rights reserved Pump Casting • Material – Casting: – Mold: CF8M Stainless Steel Sand • Weight – Clean Casting: 35 kg • Problem: – Improving yield by reducing pouring weight – Reducing machining cost Copyright © ESI Group, 2007 All rights reserved Background The example casting was part of a large transfer of patterns from another foundry These patterns came fully risered and gated Although the existing riggings yielded sound castings, it was felt that the there was opportunity for cost reductions by yield improvements and cleaning time reductions Original design: Copyright © ESI Group, 2007 All rights reserved Procedure The solidification of castings without risers was done first to determine critical thermal regions and placement of risers Simulations with risers was done next For expediency reasons Fluid Flow analysis and Modeling of Feeding aids was not done as they were considered unnecessary for the type of information we were after Initial iteration (no risers): Copyright © ESI Group, 2007 All rights reserved Second Iteration with risers This iteration shows a sound casting Porosity in this region was eliminated by adding a chill Copyright © ESI Group, 2007 All rights reserved Results In this example two iterations with risers were done Number of risers was reduced from to 5, pouring weight was reduced by 15 kg per casting and cut off and grinding surface was significantly reduced Validation with Radiography proved castings to be sound Copyright © ESI Group, 2007 All rights reserved Why Simulation is needed for Casting ? • Shorten Lead time for part development • Manufacturing Process Optimisation • Quality Improvement less scrap ã Marketing Purpose Copyright â ESI Group, 2007 All rights reserved Why ESI GROUP Casting solution ? • Recognized as Global Leader in Manufacturing Process Analysis • Expert in metallurgy / Participation in many European and International projects since 1986 • Knowledge of two technologies FDM and FEM – – • Reliable and accurate Material properties are easily accessible or computed, Unique capability in Investment casting, Sand Casting, HPDC due to ability in modeling the complete process: – Shell cooling phase – Automatic shell generator with high accuracy – Radiation effect accurately modeled – 3D Shot sleeve modeling with vacuum and air entrapment modeling – Solidification with macro/micro/gas-shrinkage prediction – Stress analysis for hot tearing, cracking, die life and part/die distortions predictions – Advanced metallurgical modules such as CAFÉ and Microstructure modeling – Very fast Parallel Version available • Upgraded versions are regularly released • Efficient worldwide customer support with local presence • Prestigious Casting reference list WW Presence in all continents Copyright © ESI Group, 2007 All rights reserved Selected Casting References • Material supplier – Alcoa, Alcan, Corus, Umicore, Kawasaki steel, Mitsubishi, Hydro, Novelis, Bao Steel, Böhler,… Mould and die designer MCS, Costamp, Bieffe, American Tool & Mould, Ehlert Tools, SPARTAN, Foundries PCC, Howmet, Grey Syracuse, Chrome Alloy, Gould Pumps, Citation, Amcast, Georg Fischer, Neimeng No Machinery Group (Baotou) Co., Ltd, Fagor Ederlan, Enkei, Daisin, Hong Fu Jin Precision Industry (TaiYuan) Co.,Ltd., Yuanqing Aluminium wheel, ANJI FOUNDRY WORKS, Dalian Heavy Industries Steel Casting Co.,Ltd, Guangzhou Seagull,… Part owner Mazda, GM, DCX, Hyundai, Yamaha Motor, Honda, Aishin, Michelin, Chrysler, PSA, Renault,… Integrated company (design/casting) RR, EMA, SNECMA, MAN, GE, P&W, Black & Decker, KWC, Canon, Denso, SALUT, Harbin Donkan Engine, SHENYANG LIMING AERO-ENGINE Group, Xi'an Aero Engine company… R&D & Universities NASA, Fraunhofer, CSM, Inasmet, ORNL, Tokyo Uni., CNRC, Centre de Haute Technologie, CTI, CTIF, Hong Kong Polytechnic University, SICHUAN UNIVERSITY, SHANXI VEHICLE ENGINE INSTITUTE, Shanghai University, Beijing University Copyright © ESI Group, 2007 All rights reserved Selected Casting References Copyright © ESI Group, 2007 All rights reserved Customer Statements Copyright © ESI Group, 2007 All rights reserved ... Reducing machining cost • Conclusion Copyright © ESI Group, 2007 All rights reserved Statement ProCAST is the leading FEM foundry simulation software, which provides coupled thermal-flow-stress... unique metallurgical capabilities, for all casting processes and castable alloys • Proven Success of ProCAST 2005 Helps ESI Group Pick Up 2006 Frost & Sullivan European Technology Leadership of the... Low Pressure Die Casting Al Direct Chill Casting Copyright © ESI Group, 2007 All rights reserved ProCAST In Action Copyright © ESI Group, 2007 All rights reserved Geometry & Meshing • Utilises