Cast designer basic

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www.c3p-group.com

About C3P-Group

� C3P Engineering Software International Co., LIMITED , a pioneer

supplier of CAX solution for industrial manufacturing processes.

� With the combination of software development, advanced analysis, extensive product development experience and cost effective local human resources, we provide industry and manufacturing business with comprehensive solutions and engineering services globally.

Authorised Distributor: Auto-Design-Online www.auto-design-online.com

with comprehensive solutions and engineering services globally.

� Our offices are located in New York, San Diego, Hongkong and Guangzhou.

� For any further details please visit www.c3p-group.com

About Distributor

� AutoAutoAutoAuto----DesignDesignDesignDesign----onlineonlineonlineonline provides corporate training and engineering

services on latest CAD-CAE software.

� Core team has extensive international experience, working closely

with European OEM like BMW, AUDI, IVECO.


� Authorised distributor of Stamping & Casting solution developed by

well known C3P Engineering Software International Co. Limited.

About Distributor

C3P Engineering Software

International Co., LIMITED

Products:

CAST DESIGNERTM


CAST ENGINEERTM

STAMP ENGINEERTM

STAMP DESIGNERTM

About Distributor

• High/Low pressure die casting

• Semi-solid casting

• Gravity sand & die casting

• Mold filling animations

• Solidification animations

• Solidification times & directions

Application

Application & objectives of C3P simulation Software

Objectives


• Gravity tilt pouring

• Investment casting

• Continuous casting

• Centrifugal casting

• Liquid stamping and Ladling

operations

• Shrinkage

• Hot spots

CAST-DESIGNER BASIC

An Expert System for High Pressure Die Casting gating system design to help designer and engineer make a reasonable die casting system in a quick way

Designer application Includes gating system , overflow, cooling and venting system

Standard alone software based on last Open CASCADE technology or fully integrated to common MCAD system, such as Pro-E, UG NX, SolidWorks etc.


MCAD system, such as Pro-E, UG NX, SolidWorks etc.

The design approach is much faster and simple compared with tradition CAD system and fully parametric

Standard and special data exchanger for 3D CAD system and CAE system

Short learning curve and enhance company design ability shortly

Application of CAST-DESIGNER

Help designer and engineer to make a better casting system design

Guide by industrial knowledge database, better quality and more reasonable

Much faster and simple compared with tradition CAD tools

Easily modify and update designed


Easily modify and update designed data

Provide an express method to modify the existed design

As pre-processor of CAE system to design/re-design the casting system geometry with fully parametric

Main Features of CAST-DESIGNER

• Standalone version and integrated version with fully integrated to MCAD system

• Start from 3D casting part in existed solid model (MCAD system) or STEP/IGES/STL format (standalone system)

• Natural and stream line design, i.e. from paper draft to 2D vector to 3D design; from inner gate, gate-runner to runner, sprue-runner and absorber;

• All design of gating, overflow, cooling and


format (standalone system)

• Powerful 3D gating system design with natural design concept, industrial know-how and knowledge

• Fully parametric design for gating and overflow system with template support, no complex F-S relationship compared with CAD system

• All design of gating, overflow, cooling and venting system in the same working environment with industrial guide

• Data exchange capability with CAD and CAE system

• Powerful, flexible, simple and easily to use, very short learn curve


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Natural Design of Gating in Cast-Designer


1 2 3

Design concept to 3D data in a quick way

It is really hard for me to make a clear

decision before I have a detail 3D casting

system…

No problem! Cast-Designer can

do that in a few minutes …


1 2 3

Cast-Designer & CPI

Cast-DesignerBasic

30 min

Cast-DesignerCPI

1 hour


Cast-DesignerBasic

15 minCast-Designer & CPI

Analysis helps make

decision

Cast-DesignerBasic

30 min

Cast-DesignerCPI

1 hour

Cast-Designer & CPI


Cast-DesignerBasic

15 min

Cast-DesignerBasic

15 min

Cast-DesignerCPI

1 hour

Designer have the opportunity to complete his design within 8 hours

Make Better Gating System -1


Gating system of Oil Panel.

Designed by 5 years experience engineer.

4 hours in UG NX.



Gating system of Oil Panel.

Designed by 1 years experience engineer.

1/2 hours in Cast-Designer..



Section area was not designed well in the original design.

Casting Zone was not correct in the original design.

Speed ratio was not very well in the original design.

Filling process of different gating system











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Casting Design Advisor

Casting Volume(metal, mass,

quality requirement)

Gating & Overflow(estimate the massRatio of casting)

Fine turning(Design finished)

Sprue runner(Nbs & section areaOyher parameters)

Gating System Design AdvisorGating System Design Advisor


Casting machine(select machine, ton, Filling ratio, piston Dia.)

Inner Gate(Nbs, section area)

Gate / Runner(Design gate runner and runner, Nbs &

section area)

Speed Up Ratio(Increase ratio of Spure:Runner :gate runner

: inner gate)

Casting Zone concept

• It is a very useful method for multi inner gate design

• The metal flow in all inner gates should balance, such as the similar max. flow distance

• Inner gate area calculated by the flow mass and filling time


filling time• Save result as inner gate

format.

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not have enough memory to open the image, or the image may have been corrupted





The image cannot be displayed. Your

computer may not have enough memory to open the image, or the image may have been corrupted

① ② ③

④

Build in Draft Design Concept

• Most effective way to bring out your design as natural thinking…

• Flexible to discuss with teachers, colleagues, leads, customers

• Design/Re-design/Modify in free style

• Internal meeting & web meeting, co-design in different location


design in different location• Suitable to complex part design

• Support many picture formats: JPG, BMP, TIF etc.

• Raster format as background• Vector format for snap with automatic converter from Raster

• Advance adjustment tools for mapping

Streamline Design

Workspace

Draft design


Gating system

Overflow

Cooling & Venting

Design check

• All functions of casting system design were summarized in one toolbar

• Streamline design from the left to right or up to down to complete a design

• Similar user interface to speedup the work affections and reduce learning curve

• Help new designer have a clear design image and guide the work


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Kernel & User’s Interface of Cast-Designer

• Build in OpenCascade technology, one of the most famous CAD kernel

• Module design style to simple operation

• Powerful 3D CAD function

• Build in OpenCascadetechnology, one of the most famous CAD kernel

• Module design style to simple operation

• Powerful 3D CAD function


function• Advance 3D solid/ surface capability

• Full integration of CAD/CAE/CAPP

• Powerful data exchanger

function• Advance 3D solid/ surface capability

• Full integration of CAD/CAE/CAPP

• Powerful data exchanger

• 3D CAD & Mesh in the same working environment

• Advance features for CAD & Mesh selection in the similar way

• Full display control for both CAD &

Kernel & User’s Interface of Cast-Designer


• Full display control for both CAD & Mesh (WF/ Color/ Shade etc.)

• Support a wide range element types (1D/ 2D/ 3D)

• Complete mesh operation functions

• Many advance mesh functions for defined application

Cast-Designer for MCAD• Cast-Designer build in the existed CAD system

• Familiar working environment, save learning time

• No data transfer problems. The system handle all the


2004~ 2010SolidWorks

17 ~ NX 7UG NX

2000 ~ WF5Pro-ENGINEER

SUPPORT VERSI ONSCAD SYSTEM

2004~ 2010SolidWorks

17 ~ NX 7UG NX

2000 ~ WF5Pro-ENGINEER

SUPPORT VERSI ONSCAD SYSTEM

problems. The system handle all the data automatically to avoid data lose

• Better integration with design data management capability

• Full function as standard software version and widely CAD version support

Different of standalone & MCAD version

Start pointCasting System

Design

Couple to

CPI/CAE

Couple to

CAD/CAM

Existed 3D CAD

part in STEP/ IGES

/STL format.

Not recommended

STD

Same working

environment.

Special designed

technology to

Very good!

Same working

environment with

full mesh functions.

OK! But need do

some fine turning,

(Boolean, fillet,

sew, partition etc.)


Not recommended

to design a full

casting from zero,

repair is possible.

MCAD

Same as standard

3D CAD software, it

is used in industrial

for product & mould

design widely with

a lots of learning

material.

technology to

speed up the

casting system

design.

A plug in window in

MCAD system

also with data

management.

Same interface

and function as

standard version.

full mesh functions.

Special technology

in meshing for

defects of CAD.

Possible, but

limited to mesh

function usually.

Except also with

Cast-Design CPI

for MCAD system

together.

Very good!

No data lose and

can enjoy all fine

turning functions of

CAD system, and

sometimes it is

more advance.

sew, partition etc.)

Some function is

time consuming if

the geometry is

complex.


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Full Integrated CAX Environment


• Complete CAD functions from basic primitives, Vertex, surface & solid generation to CAD transformation, Boolean operation & Check.

• Full range mesh generation & operation functions, include 1D/2D/ 3D manual-Auto generation, mesh transformation & info. check.

Gating System Designer

Inner gate

shock absorberWorkspace

Draft design

Overflow


Sprue runner

Inner gate

Gate runner

RunnerGating system

Overflow

Cooling & Venting

Design checkPiston

Gating system design procedure

Casting Design Advisor

Inner gate & centre of piston location

Casting-Zone analysis (if any)


Runner, Gate-Runner trace define

Detail parameter define and turning

Overflow, cooling & venting design

Design Check & Evaluation


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Cast-Designer Working procedure

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Work Space / Part plane

Draft Design

Load draft from BMP, JPG, TIFConvert bitmap to vectorAdvance tools for CAD match

Easy to draft, snap, dimensionCAD method or mesh method


Advance tools for CAD match

Natural draft concept in Cast-Designer


Load in draft as

background

(Raster format)

Natural draft concept in Cast-Designer


Load in draft and convert to vector objects

Gate System Design � (General)

Streamline design process

The image cannot be displayed. Your computer may not have enough memory to open the image, or the

image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.

• Each design can be assigned to a project name for data manage, multi-plans and multi-versions is possible

• Work plane and location could be set as general in


could be set as general in one button and also possible to modify it in separate

• Support gate system geometry operation to speed up design (translation, rotation and symmetry)

• Support gate system template and data exchange(save, load, import, export)

Gate System Design � (General)The image cannot be displayed. Your computer may not have enough memory to open the image, or the

image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.

• Choose the type of shot machine from the data base

• Choose type of chambers• Wide data base of the

manufacturer• According to the machine,


• According to the machine, it will automatically consider the other required details e.g. piston dia, ton filling ratio etc.

• Similar interface for all components • 1 Object list, 2 Data table• 3 Properties, 4 Coordinates• 5 Function button

• Multi-objects support• WYSWYG (What You See, What

You Get), both 2D and 3D preview• Flexible coordinate adjusting

1

3

Gate System Design � (Inner Gate)


• Flexible coordinate adjusting• Online tips and area checking

2

5

4

• Inner gate data management



• Inner gate data management• Quick design transformation

• Translation, Rotation, mirror• Online tips and section area

checking, velocity vector preview• Online tens year industrial

experience & know-how to guide the design • Filling velocity & filling time base on casting metal and wall thickness

• Advance filling time calculatorsuggested by NADCA. The fillingtime with a high accurate since itis also consider the qualityrequirement of casting products.



• Ingate evaluation to helpdesign/check inner gate basedon casting metal and geometry,it is widely approved in realmould industry.

Online velocity vector preview bases on simple geometry calculation. It could be used to,

Inner gate filling angle checkCasting zone checkUnfilled zone check

Since this is a very rough evaluation



Since this is a very rough evaluation it is recommended to have a detail CPI analysis for detail.

• Very Similar interface as inner gate design

• WYSWYG (What You See, What You Get), both 2D and 3D preview

1

3

Gate System Design � (Gate Runner)


You Get), both 2D and 3D preview• Online runner design wizard

5

4

3

2



• Full parameters for complex design• User defined trace feature line• Sections, Start & last angle• Sections & sweep method, smoothing or not, automatic connection

Pre-defined gate-runner/runner: Straight sided, curve sided and tangential. Full parameters control and simple/fast setup.



WL WR

Draft Angle L Draft Angle R D

O (X,Y, Z)

� Complete parameters for gate-runner: 2 parameters for draft angle (DraftL, DraftR), 2 parameters for runner width (WL, WR);

� Triangle section is possible depend the input data (Angles & width).

� Flexible adjust tools for



� Flexible adjust tools for both coordinate and width.

� Complex gate runner/runner trace could be designed by picking pre-defined curve directly.

� Parameters of start & end sections could be defined in setup wizard.

� Section Nbs. Could be assigned by user as the complex ratio of runner

Design Complex Gate Runner TraceDesign Complex Gate Runner Trace



as the complex ratio of runner � Multi gate runners could be connected

automatically based on the geometry.

Multi-segments Runner


Powerful runner wizard and runner link


Example: Runner design


Example: Runner design


Gate System Design � (Gate runner)

� With full capability of 3D gate runner/ runner design.

� One-direction 3D runner (plan in width direction) could be designed directly as usual.

� Full 3D runner (it is also curved in width direction) could be designed

3D Gate Runner/ Runner Capability3D Gate Runner/ Runner Capability


width direction) could be designed as above then use ‘Extrusion’ to extend up/down surface then cut it in the parting plane (curved surface)

The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.

The image cannot be displayed. Your computer may not have enough memory to open the image, or the image may have been corrupted. Restart your computer, and then open the file again. If the red x still appears, you may have to delete the image and then insert it again.

Example for fully 3D Gate Runner designExample for fully 3D Gate Runner design

Gate System Design � (Gate runner)


Define parting surface, it is a 3D

surface

Define the gating system as usual

(plan in width direction of runner)

‘Extrusion’ the runner and cut it in parting surface to obtain the

final design

Gate System Design � (Runner design)

• Very Similar interface and design method as gate runner

• Suitable simple shape and long flow path (WL=WR)


path (WL=WR)• Online runner design wizard

� Useful tools to check the gate runner /Runner design, ensure the design is correct.

� Detail information of the section location, area and increase/ decrease ratio.

Section EvaluationSection Evaluation

Gate System Design � (Runner design)


location, area and increase/ decrease ratio.

� Adjust the design/Dimension immediately and recheck the data again.

� Support cold chamber, hot chamber casting machine and no spruerunner design.

� Full parameter for sprue-runner;Support multi sprue runner design

Gate System Design � (Cold Chamber)

1

2

4


� Support multi sprue runner design� WYSWYG.� Online evaluation for casting

process and machine selection.

3

� Support cold chamber, hot chamber casting machine and no spruerunner design.

� Full parameter for sprue-runner;Support multi sprue runner design

1

2

4

Gate System Design � (Hot Chamber)


� Support multi sprue runner design� WYSWYG.� Online evaluation for casting

process and machine selection.

3

Plunger EvaluationPlunger Evaluation

Gate System Design � (Spure Runner)


Process parameter

Machineselection

� Full parameters for absorber;� Support Multi group definition.� WYSWYG.

Gate System Design � (shock absorber)

1


2


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� Standardized, full parametric, flexible location and rotation

� Build in overflow type: rectangular, orbicular and wedge, pre-defined data template to speed up definition.

� Support multi group overflows with

Overflow design (Standard design)

Very effective and flexible way to design overflow system

1


� Support multi group overflows with data management capability

� Design data operation (translation, rotation, mirror, extrusion …)

� Overflow data exchange (I/O)� Support customization template

2

• Flexible method for overflow position and location (fix side or movable side or both side)

• Design data export and import and support customized template

Overflow design (Standard design)


• To design non-standard overflow upon casting geometry or others

• Define base plane profile of overflow as an edge or wire

• Define the basic overflow parameters (depth, draft angle and extrusion direction etc.)

• Define central line of overflow gate (line, gate width and depth)

Overflow design (Non-Standard design)


• Define central line of overflow gate (line, gate width and depth)

• Define the overflow location type (fix or movable half )

� Pre-defined centre line for cooling

Cooling channel design


� Pre-defined centre line for cooling channel (2D/3D Import or draft in Cast-Designer)

� Flexible 3D lines operation� Section shape and dimension control� Support multi channels and multi section

area definitions, fully parametric design� Automatically CAD Boolean operation� Cooling channel advisor for channel

length & diameter and HTC calculator

� Cooling channel calculator to calculate cooling line length and diameter based on industrial approval formula

� Build in heat transfer coeff.

Cooling Channel CalculatorCooling Channel Calculator

Cooling channel design


� Build in heat transfer coeff. (HTC) calculator

� Mould mass and cooling could be considered

� Heat affection rate could be considered

Venting channel design


� Pre-defined centre line for venting channel (2D/3D Import or draft in Cast-Designer)

� Section shape and dimension control� Support multi channels and multi section

area definitions, parametric design� Automatically CAD Boolean operation� Support draft angle and partition plane

Venting block design


� Venting block design in die casting to support vacuum system;

� Full parameter design ;� Flexible position and location control;� Preview function, WYSWYG� Design date export and import, support

customized template� Link with venting channel easily

Gate System Checking

Section CheckingSection Checking

Filling RatioFilling Ratio

Casting YieldCasting Yield

Shot CheckingShot Checking



� Checking the section area in defined cut direction for any 3D geometry

� Define sections number and distance of each section

� This checking is important and absolutely necessary for complex geometry, such as multi-runner with Boolean operation in different direction





MachineSelection



Processparameter


� Database with more than 200 machines and easily to expend more by user

� Select correct piston diameter and chamber length to achieve a reasonable filling ratio

� Predict the 1st and 2nd speed to avoid chamber gas problem

� Calculate the position and time for critical accelerate point;

� Machine capability evaluation.





� Casting yield checking to compare with industrial requirement

� Predict locking force for machine selection

� Evaluate machine capability bases on part geometry, casting metal and product quality requirement





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Cast-Designer result data

• Design data was a set of solid components assigned by defined name

• Solid components were not combined together, it could be done by user if necessary

• It is possible and often


Useful tools for geometry fine turning

• It is possible and often for initiation design: CAD overlay, intersection, tin gaps … it could be treated only after the design plan was confirmed (time consuming sometimes )

• Cast-Design provides a set of tools to combine the objects and fine turning the design

CAD SewBoolean operation

Fillet Chamfer Partition Glue

Cast-Designer result (Geometry turning)

• Unnecessary to fuse solid components, only select the ‘Multi domain’ option in fast meshing

• Make fillet for big dimension which may affect the metal flow (i.e. sprue runner), unnecessary for small fillet

Initial design

Prepare data for CPI/CAE AnalysisPrepare data for CPI/CAE Analysis


Initial design

Geometry turning

Prepare data for CAD modelingPrepare data for CAD modeling

• Fuse solid components is necessary usually, also ask to sew the surface for same surface

• Make fillet is necessary and it is time consuming some times

• It is always suggest to export the gating, overflow and cooling system in STEP format to MCAD system for geometry combine and fillet or select Cast-Designer MCAD version.

Cast-Designer Data Exchange

STEP IGESBREP

CAD General CAE System

STL DXF

Cast-EngineerAnsysPro-CASTNastran

STLPatranIdeas (UNV)OFF

CAD GeneralCAD General CAD General CAE SystemCAE System


CAM System

CATIA UGPro-E SolidWorksParaSolid

Nastran OFF

STL

Extra license required

CAD AdvanceCAD Advance CAM SystemCAM System

Export design data to other CAD system

• The design data of Cast-Designer could be exported to other CAD system in 3D Solid objects directly• Support export format： STEP, IGES, BREP

• The recommended export formats for gating system are STEP or BREP, both types file have best geometry quality

• It is recommended to export all components in one STEP file without Boolean operation

• Notice for exporting Cast-Designer to a sole solid/part CAD


• Notice for exporting Cast-Designer to a sole solid/part CAD system – Please select sole solid/part than assembly，then the system will

carry out Boolean operation for all the components automatically and get a sole part (i.e. PRO-E, CATIA etc.)

– System recognizes all the solids and convert to multi files with one file one solid, the user need load one of the above file and insert the others one by one, after that the system will carry out Boolean operation automatically and get an one sole part (i.e UG NX, SolidWorks)


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Cast-Designer Snapshot

Cooling feature line



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Couple Cast-Designer with simulation software

• What CAE can do?– Bases on Input data, provides output result– Detail casting process information: metal filling, solidification, stress etc. What CAE can not do?

– Modify the existed model geometry directly– Fast modify the existed design plan as CAE result


– Fast modify the existed design plan as CAE result • Cast-Designer can couple to any CAE system as a pre-process for casting system design or modification, whatever FEM or FDM/FVM code.• Cast-Engineer, MAGMA, Pro-CAST, Flow3D, AnyCasting, QUICKCAST, NOVACAST, JSCAST …

• Supports STEP/IGES/STL and many mesh formats


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Major Benefits of CAST-DESIGNER

Very fast design speed

Easy to use

General design time in Cast-Designer：Standard casting � Ten minute to one hour Complex 3D partition surface � 1~2 hour


Easy to use

Streamline design methodSimilar interface for all components Full parametric design, pre-defined template

Natural design styleNatural design style, draft design approachSupport multi design plans

Fully CAD/CAE/MCAD integration

Design checking and evaluation

CAD Import/export (STEP, IGES, STL)CAM export (STL)MCAD version built in CAD environment

Major Benefits of CAST-DESIGNER


Design checking and evaluationOnline guide and wizardSpecial tools for design checking and evaluation

Easily customization

Design database generation and customization

THANK YOU!

Contact


For any further query please contact us

Email: [email protected]

SKYPE: autodesignonline

Web: www.auto-design-online.com

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Cast designer basic