cast designer basic deatails

7/27/2019 cast designer basic deatails

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Authorised Distributor: AutoAutoAutoAuto----DesignDesignDesignDesign----OnlineOnlineOnlineOnline www.auto-design-online.com


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Authorised Distributor: AutoAutoAutoAuto----DesignDesignDesignDesign----OnlineOnlineOnlineOnline www.auto-design-online.comwww.c3p-group.com


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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 localhuman resources, we provide industry and manufacturing business

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

w compre ens ve so u ons an eng neer ng serv ces g o a y.

Our offices are located in New York, San Diego, Hongkong andGuangzhou.

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


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About Distributor

AutoAutoAutoAuto----DesignDesignDesignDesign----onlineonlineonlineonline provides corporate training and engineeringservices 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.


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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


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CAST-DESIGNER BASIC

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

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

Standard alone software based on last OpenCASCADE technology or fully integrated to common

-


, , , .

The design approach is much faster and simplecompared with tradition CAD system and fullyparametric

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

Short learning curve and enhance company designability shortly


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Application of CAST-DESIGNER

Help designer and engineer tomake a better casting systemdesign

Guide by industrial knowledgedatabase, better quality and morereasonable

Much faster and simple comparedwith tradition CAD tools


Easily modify and update designeddata

Provide an express method tomodify the existed design

As pre-processor of CAE system to

design/re-design the castingsystem geometry with fullyparametric


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Main Features of CAST-DESIGNER

Standalone version andintegrated version with fullyintegrated to MCAD system

Start from 3D casting part inexisted solid model (MCADsystem) or STEP/IGES/STLformat (standalone system)

Natural and stream linedesign, i.e. from paper draftto 2D vector to 3D design;

from inner gate, gate-runnerto runner, sprue-runner andabsorber;

All design of gating,


Powerful 3D gating systemdesign with natural designconcept, industrial know-howand knowledge

Fully parametric design forgating and overflow systemwith template support, nocomplex F-S relationshipcompared with CAD system

overflow, cooling andventing system in the sameworking environment withindustrial guide

Data exchange capabilitywith CAD and CAE system

Powerful, flexible, simpleand easily to use, very shortlearn curve


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Natural Design of Gating in Cast-Designer


1 2 3


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Cast-Designer & CPI

Cast-DesignerBasic

30 min

Cast-DesignerCPI

1 hour


Cast-DesignerBasic

15 minCast-Designer & CPI

Analysis helps make

decision


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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 tocomplete his design within 8 hours


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Make Better Gating System -1


Gating system of Oil Panel.Designed by 5 years experience engineer.

4 hours in UG NX.


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Gating system of Oil Panel.

Designed by 1 years experience engineer.

1/2 hours in Cast-Designer..


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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.


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Filling process of different gating system



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Casting Design Advisor

Casting Volume(metal, mass,

quality requirement)

Gating & Overflow(estimate the mass

Ratio 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 runnerand runner, Nbs &

section area)

Speed Up Ratio(Increase ratio of Spure:

Runner :gate runner

: inner gate)


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Casting Zone concept

It is a very useful methodfor multi inner gate design

The metal flow in all innergates should balance, suchas the similar max. flowdistance

Inner gate area calculatedby the flow mass and


i ing time Save result as inner gate

format.

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nothaveenoughmemory to opentheimage,or theimagemay havebeen corrupted





Theimagecannotbedisplayed.Your

computer maynothaveenoughmemory to opentheimage,or theimagemay havebeen corrupted


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Build in Draft Design Concept

Most effective way to bring out yourdesign as natural thinking

Flexible to discuss with teachers,colleagues, leads, customers

Design/Re-design/Modify in freestyle

Internal meeting & web meeting, co-desi n 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


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Streamline Design

Workspace

Draft design


Gating system

Overflow

Cooling & Venting

Design check

All functions of casting system designwere summarized in one toolbar Streamline design from the left to

right or up to down to complete adesign

Similar user interface to speedup thework affections and reduce learningcurve

Help new designer have a clear design

image and guide the work


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Kernel & Users Interface of Cast-Designer

Build in OpenCascadetechnology, one ofthe most famousCAD kernel

Module design styleto simple operation

Powerful 3D CAD

Build in OpenCascadetechnology, one ofthe most famousCAD kernel

Module design styleto simple operation

Powerful 3D CADfunction


Advance 3D solid/surface capability

Full integration ofCAD/CAE/CAPP

Powerful dataexchanger

Advance 3D solid/surface capability Full integration of

CAD/CAE/CAPP Powerful data

exchanger


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Cast-Designer for MCAD Cast-Designer build

in the existed CADsystem

Familiar workingenvironment, savelearning time

No data transferroblems. 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

system handle all thedata automatically toavoid data lose

Better integrationwith design data

managementcapability Full function as

standard softwareversion and widely

CAD version support


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Full Integrated CAX Environment


Complete CAD functions from basicprimitives, Vertex, surface & solidgeneration to CAD transformation,Boolean operation & Check.

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


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Gating System Designer

shock absorberWorkspace

Draft design

Overflow


Sprue runner

Gate runner

RunnerGating system

Overflow

Cooling & Venting

Design checkPiston


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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 vector

Easy to draft, snap, dimensionCAD method or mesh method


vance too s or matc


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Natural draft concept in Cast-Designer


Load indraft as

background

(Rasterformat)


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Natural draft concept in Cast-Designer


Load indraft andconvert

to vectorobjects

G S D i (G l)


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Gate System Design (General)

Streamline design process

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imagemay havebeen corrupted.Restartyour computer,and then open thefileagain. Ifthered x stillappears,you may haveto deletetheimageand then insertitagain.

Each design can be assigned

to a project name for datamanage, multi-plans andmulti-versions is possible

Work plane and location


cou e set as genera in

one button and also possibleto modify it in separate

Support gate systemgeometry operation tospeed up design (translation,rotation and symmetry)

Support gate systemtemplate and data exchange(save, load, import, export)

G S D i (G l)


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Gate System Design (General)Theimagecannot bedisplayed.Your computer may nothaveenough memory to open theimage,or the

imagemay havebeen corrupted.Restartyour computer,and then open thefileagain. Ifthered x stillappears,you may haveto deletetheimageand then insertitagain.

Choose the type of shotmachine from the data

base Choose type of chambers Wide data base of the

manufacturer


,

it will automaticallyconsider the otherrequired details e.g. pistondia, ton filling ratio etc.

G t S t D i (I G t )


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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 ad ustin

1

3

Gate System Design (Inner Gate)


Online tips and area checking

2

5

4



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Quick design transformation Translation, Rotation, mirror Online tips and section area

checking, velocity vector preview Online tens year industrial

experience & know-how to guidethe design Filling velocity & filling time

base on casting metal andwall thickness



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Advance filling time calculatorsuggested by NADCA. The fillingtime with a high accurate since itis also consider the quality

requirement of casting products.



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



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Online velocity vector preview baseson simple geometry calculation. Itcould be used to,

Inner gate filling angle checkCasting zone checkUnfilled zone check



it is recommended to have a detailCPI analysis for detail.

Gate System Design (Gate Runner)


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Very Similar interface as innergate design

WYSWYG (What You See, WhatYou Get), both 2D and 3D review

1



Online runner design wizard

5

4

3

2



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Full parameters for complex design User defined trace feature line Sections, Start & last angle Sections & sweep method, smoothing

or not, automatic connection



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





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WL WR

Draft Angle L Draft Angle RD

O (X,Y, Z)

Complete parameters forgate-runner: 2 parametersfor draft angle (DraftL,DraftR), 2 parameters for

runner width (WL, WR); Triangle section is possibledepend the input data(Angles & width).



both coordinate and width.



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Complex gate runner/runner trace couldbe designed by picking pre-defined

curve directly. Parameters of start & end sectionscould be defined in setup wizard.

Section Nbs. Could be assigned by user

Design Complex Gate Runner TraceDesign Complex Gate Runner Trace



Multi gate runners could be connectedautomatically based on the geometry.

Multi-segments Runner


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Multi-segments Runner


Powerful runner wizard and runner link


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Powerful runner wizard and runner link


Example: Runner design


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Example: Runner design



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Gate System Design (Gate runner)


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With full capability of 3D gaterunner/ runner design.

One-direction 3D runner (plan inwidth direction) could be designeddirectly as usual.

Full 3D runner (it is also curved in

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


as above then use Extrusion toextend up/down surface then cut itin the parting plane (curved surface)



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Theimagecannot bedisplayed.Your computer may nothaveenough memory to open theimage,or theimagemay havebeen corrupted.Restartyour computer,and then open thefileagain.If thered x stillappears,you may haveto deletetheimageand then insertitagain.Theimagecannot bedisplayed.Your computer may nothaveenough memory to open theimage,or theimagemay havebeen corrupted.Restartyour computer,and then open thefileagain. Ifthe red x stillappears,you may haveto deletetheimageand then insertitagain.

Theimagecannot bedisplayed.Your computer may nothaveenough memory to open theimage,or theimagemay havebeen corrupted.Restartyour computer,and then open thefileagain.If thered x stillappears,you may haveto deletetheimageand then insertitagain.

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



Define partingsurface, it is a 3D

surface

Define the gatingsystem as usual

(plan in width directionof runner)

Extrusion the runnerand cut it in parting

surface to obtain thefinal design

Gate System Design (Runner design)


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Very Similar interface and designmethod as gate runner

Suitable simple shape and long flowath (WL=WR)


Online runner design wizard



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Useful tools to check the gate

runner /Runner design, ensure thedesign is correct.

Detail information of the sectionlocation, area and increase/

Section EvaluationSection Evaluation



decrease ratio.

Adjust the design/Dimensionimmediately and recheck the dataagain.

Gate System Design (Cold Chamber)


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Support cold chamber, hot chambercasting machine and no spruerunner design.

Full parameter for sprue-runner;

Gate System Design (Cold Chamber)

1

2

4


Support multi sprue runner design

WYSWYG. Online evaluation for casting

process and machine selection.

3

Gate System Design (Hot Chamber)


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Support cold chamber, hot chambercasting machine and no spruerunner design.

Full parameter for sprue-runner;

1

2

4

Gate System Design (Hot Chamber)


Support multi sprue runner design

WYSWYG. Online evaluation for casting

process and machine selection.

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Gate System Design (Spure Runner)


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Plunger EvaluationPlunger Evaluation

y g ( p )


Process

parameter

Machineselection

Gate System Design (shock absorber)


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

y g ( )

1


2


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Overflow design (Standard design)


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Standardized, full parametric,flexible location and rotation

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

Very effective and flexible way todesign overflow system

1


data management capability

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

Overflow data exchange (I/O) Support customization template

2

Overflow design (Standard design)


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Flexible method for overflowposition and location (fix side ormovable side or both side)

Design data export and import and

support customized template


Overflow design (Non-Standard design)


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To design non-standard overflowupon casting geometry or others

Define base plane profile ofoverflow as an edge or wire

Define the basic overflowparameters (depth, draft angle andextrusion direction etc.)

Define central line of overflow gate


(line, gate width and depth)

Define the overflow location type(fix or movable half )

Cooling channel design


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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 design


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Cooling channel calculator to

calculate cooling line length anddiameter based on industrialapproval formula

Build in heat transfer coeff.

Cooling Channel CalculatorCooling Channel Calculator


(HTC) calculator

Mould mass and cooling could beconsidered

Heat affection rate could beconsidered

Venting channel design


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

Section shape and dimension control

Support multi channels and multi sectionarea definitions, parametric design Automatically CAD Boolean operation Support draft angle and partition plane

Venting block design


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Venting block design in die casting tosupport 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


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Section CheckingSection Checking

Filling RatioFilling Ratio

Casting YieldCasting Yield


Checking the section area indefined cut direction for any3D geometry

Define sections number anddistance of each section

This checking is important andabsolutely necessary forcomplex geometry, such asmulti-runner with Booleanoperation in different direction



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Shot CheckinShot Checkin

MachineSelection


Process

parameter

Database with more than 200machines and easily to expendmore by user

Select correct piston diameterand 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.



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Casting yield checking to compare withindustrial requirement

Predict locking force for machine

selection Evaluate machine capability bases onpart geometry, casting metal andproduct quality requirement


o ec ngo ec ng


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Cast-Designer result data


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Design data was a set ofsolid components assignedby defined name

Solid components were

not combined together, itcould be done by user ifnecessary


Useful tools for geometry fine turning

for initiation design: CADoverlay, intersection, tingaps it could be treatedonly after the design planwas confirmed (timeconsuming sometimes )

Cast-Design provides aset of tools to combinethe objects and fineturning the design

CAD SewBoolean operation

Fillet Chamfer Partition Glue

Cast-Designer result (Geometry turning)


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Unnecessary to fuse solid components, onlyselect the Multi domain option in fastmeshing

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

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 formatto MCAD system for geometry combine andfillet or select Cast-Designer MCAD version.

Cast-Designer Data Exchange


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STEP

IGESBREP

CAD General CAE System

STL

DXF

Cast-Engineer

AnsysPro-CAST

STL

PatranIdeas (UNV)

CAD GeneralCAD General CAD GeneralCAE SystemCAE System


CAM System

CATIA UGPro-E SolidWorksParaSolid

STL

Extra licenserequired

CAD AdvanceCAD Advance CAM SystemCAM System

Export design data to other CAD system


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The design data of Cast-Designer could be exported to otherCAD 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


ot ce or export ng ast- es gner to a so e so part

system Please select sole solid/part than assemblythen the system will

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

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


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Cast-Designer Snapshot


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Cooling feature line



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Couple Cast-Designer with simulation software


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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


as mo y e ex s e es gn p an as resu

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


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Very fast design speed

Eas to use

General design time in Cast-Designer

Standard casting

Ten minute to one hourComplex 3D partition surface 1~2 hour


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

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

Major Benefits of CAST-DESIGNER


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Fully CAD/CAE/MCAD integration

CAD Import/export (STEP, IGES, STL)

CAM export (STL)MCAD version built in CAD environment


Online guide and wizardSpecial tools for design checking andevaluation

Easily customizationDesign database generation and customization

Contact


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THANK YOU!


For any further query please contact usEmail: [email protected]

SKYPE: autodesignonline

Web: www.auto-design-online.com

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cast designer basic deatails