Getting Started With QC (Sand Casting)

8/18/2019 Getting Started With QC (Sand Casting)

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Getting startedwith

QuikCAST

™

(Sand Casting)

Engineering Simulation forIndustry


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2ESI Grou Co ri ht © ESI Grou 2008. All ri hts reserved.

Getting Started with QuikCAST™List of CAD Files

Casting.STL

Chill.STL

Exo_Sleeve.STL


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Getting started with

QuikCAST

™Import CAD Files (Casting)

1 Select New option from the File Menu

Browse to definethe Study Location

2 Input Study Name

3

4 Click OK

5

Browse and select thecasting component STL file «casting.STL »

6 Click Open to load the CADfile in the model Window

7

Activate Welding Point Operation

Define CAD File Unit System

8

9

10

Input Tolerance value (mm)

Activate Automatic Fixing

11 Click OK

12 Click YES to continue

Give a description of theencountered problem whenanalysing the CAD files

13 Click YES to continue

All the problems detectedduring the analysis have beenautomatically fixed

Casting CAD geometry has been succefully imported


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QuikCAST

™Import the CAD (Chills)

1 Select Import Option from the File Menu

2 Browse and select the CADfile « chill.STL »

3

Click Open to load the newCAD file in the model Window

4 Activate Automatic Fixing

5 Click OK

Click OK 6

No problems detected whenanalysing the Chill geometries

Chills have been successfully imported


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QuikCAST

™Import the CAD (Sleeves)

1 Select Import Option from the File Menu

2 Browse and select the CAD file« exo_sleeve.STL »

3

Click Open to load the new CADfile in the model Window

4 Activate Automatic Fixing

5Click OK

Click OK 6

No problems detected whenanalysing the Sleeve geometries

Sleeves have been successfully imported


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QuikCAST

™ Automatic CAD Inlet Creation

Select Mesh Basic Shapes Option from the Model Menu

Select By extrusion option1

2 Input Extrusion Distance

3Switch to Wire&Shadeddisplay mode to display thefacets

4

Entity selection mustbe set to Facet

5

Select Facets locatedon the top of the tube

( SHIFT + leftbutton)

> Extruded geometry isautomatically displayed

for each new selectedfacet

6 Click Apply when allthe facets located atthe top have been

selected

Click CloseThe inlet volume has

been succefully created

7


7/267ESI Grou Co ri ht © ESI Grou 2008. All ri hts reserved.

Getting started with QuikCAST™ Automatic CAD Mold Creation

Select Create Mold Option from the Model MenuThe External mold contour is displayed in red

1

Adjust the mold maximum limit in the Z direction inorder to fit with the top of the tube

Switch to the X- View

2

3 Click Apply

External Mold Definition has been successfullycreated



Getting started with QuikCAST™Import the CAD (Exothermic Sleeves)

In order to detect/assign volume materialsSelect Domain Manager Option from the Model Menu


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Getting started with QuikCAST™ Automatic Volume detection/Material Assignment

Activate the Create Contact surface option

Click Start to Start the Automatic Volumedetection

2

1

11 Volume domains have been detected thatneed to be renamed and assigned with materialproperties.New Surface Domains have beenautomatically created because the CreateContact surface option has been activated

Select Volume_001 (leftclick )

1

2

Click View Volume todisplay the Volume_001

Click Rename

3

Input Volume Domain Name

4

Repeat the steps

to rename the 11 volumes

1 2 3 4

Click Material

5

6 Select Alloy Volumetype

7

8

Activate Sandard DB

Select GGG_40 Materialfrom the material list

Repeat thestepsto assign materials to the alloyand mold volumes

5 6 7 8 Activate Priority order. Click P9Change Volume Priority order with the

arrows Alloy volumes first positions ( filling order)Mold volume ( last position)

10 Click Remove to delete surface domainscreating during the import and during theautomatic fixing sequence

11 Activate Surface Domain panel12



Getting started with QuikCAST™3D Grid/FD Mesh Generation

Activate Simplify Method1

Select all the volumes except themold volume

2

Input Mininum Size to fixglobal grid cell size

3

Click Apply to generate theGrid definition

4

Click Run to generate the 3D Mesh5



Getting started with QuikCAST™Define Gravity Direction

Select Gravity Option from the Process Menu

Select PositiveZ direction and check Gravity Direction ( displayed in green) inthe model window

1

2 Click OK



Getting started with QuikCAST™Start the Model Set-up

Select Input Data Check Model Option from the Process Menu andthe Input Data Check window will appear on the left



Getting started with QuikCAST™Set-up the Metal Flow

1 Select Fluid Rate BC ( left click ) to set up the initial fluid rate for the filling

2 Click and Select Add option ( right click ) to open the panel definition

3 Activate Imposed Option

4

5 Click OK

Select « Inlet » Volume in

the Volume list (left click)



Getting started with QuikCAST™Initialize the Metal Flow

1 Select Velocity BC ( left click ) to initialize fluid flow in the inlet volume

2 Click and Select Add option ( right click ) to open the panel definition3

4

5 Click OK

Select the Surface domainthat corresponds to the topof the inlet volume

Enter a Velocity Valuedefined in m/s



Getting started with QuikCAST™Set Up the Air flow BCs

1 Select Permeability BC ( left click ) to set-up the air flow inside the casting


3

5

6

Select the Surfacedomain that correspondsto the interface betweenthe casting and the mold

Input Sand GF index

Click OK

Input Average Mold thickness4



Getting started with QuikCAST™Set-Up the Wall Roughness

1 Select Surface Roughness BC ( left click ) to set-up wall rugosity

Click and Select Add option ( right click ) to open the panel definition2

3

4

5

Select the Surface domain thatcorresponds to the interface

between the casting and themold

Input Roughness index(0.05 for Sand Mold)

Click OK



Getting started with QuikCAST™Set-Up the Metal Temperature

1 Select Temperature BC ( left click ) to set-up the pouring metal temperature


Activate Filling / DeactivateSolidification

3

4

5

Input Metal PouringTemperature

Activate Imposed (Metal pouringtemperature remainsconstant)

Click OK tovalidate

5 Activate Filling / DeactivateSolidification

6 Activate Volume Domain List

7 Select Inlet Volume



Getting started with QuikCAST™Set-Up the Thermal exchange with the External

1


1 Enter External Ambiant Temperature

5

Enter Emissivity Value2

3 Activate Filling and Solidification

4 Select External Mold Surface Domain

Click OK



Getting started with QuikCAST™Set-Up the Thermal Exchange at the interface Alloy-Mold

1 Select Contact Resistance BC ( left click ) to set-up the air flow inside the casting


4 Click OK

1Enter Thermal Resistance value to adjustthe thermal exchange at the interfacecasting/mold

2 Activate Filling

3 Select the Surface Domain thatdescribes the interface alloy-mold



Getting started with QuikCAST™Run the Calculations

Select Calculation Start Option from the Calculation Menu

4

Activate None option to run astandard flow calculation

1 Activate Standard Calculation Option

2 Enter Air temperature inside thecavity (cavity is empty)

3 Enter Mold temperature

5

Enter Filling and Solidification StopCriterias ( Time and Temperature)

Click RUN to start the calculation> Opens the Monitor Calculation Window

7

6

Calculation is running now


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Getting started with QuikCAST™Post-Processing Metal Temperature (Visual-CAST)

Select Open option from the File Menu

Select Volume to load

1

Click OK 2

Select Snapshot option from theResults menu

3


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Getting started with QuikCAST™Post-Processing Metal Temperature (Visual-CAST)

Select THERMAL in Categories and Temperature inResults to display the temperature results during thefilling and solidification

4

5 Select Update to update the last calculated results

6 Select Arrows to display the differents states


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Getting started with QuikCAST™Post-Processing Feeding during solidification (VISUAL)

To analyse the mushy+liquid pockets feeding, selectSolid Fraction Contour

1

Click Cut off Icon to open the cut-offparameter panel

3

Activate Cut Off Option2

Enter Minimum Cut off Solid Fraction Value4

Results are now displayed in the cut-off mode

Activate Below min Option5

Click Contour to go back to the Contour Panel6


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Getting started with QuikCAST™Post-Processing Porosity (VISUAL)

Select Skrinkage Contour1

Click cut-off icon to adjust cut-off value thatneeds to be used for shrinkage

2

Input Max value for cut-off shrinkage3

4 Activate Above Max option

5 Activate Above Max option


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Getting startedwith QuikCAST™

(Sand Casting)

Engineering Simulation forIndustry

Documents

Getting Started With QC (Sand Casting)