C3P Casting Simulation Software

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Authorised Distributor: Auto-Design-Online www.auto-design-online.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 local
human resources, we provide industry and manufacturing business
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

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About Distributor
Auto-Design-
Auto-Design-online 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.

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About Distributor
C3P Engineering Software
International Co., LIMITED
Products:
CAST DESIGNERTM

CAST ENGINEERTM

STAMP DESIGNERTM

STAMP ENGINEERTM
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About Distributor
Application & objectives of C3P simulation Software
Application Objectives
• High/Low pressure die casting • Mold filling animations
• Semi-solid casting • Solidification animations
• Gravity sand & die casting • Solidification times & directions
• Gravity tilt pouring • Shrinkage
• Investment casting • Hot spots
• Continuous casting
• Centrifugal casting
• Liquid stamping and Ladling
operations
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Concept of Casting Process Insight (CPI)
• Cast-Designer CPI is a powerful tool integrated in MCAD
system based on the last CAE technology
– Analysis the metal filling and solidification process
– Provide an accurate, express and flexible method for gating
system evaluation, select the ‘right’ design
– Casting zone concept and part wall thickness analysis
– Innovation technology compared with tradition CAE method,
upfront analysis, accurate, flexible and no limitation.
• CPI is the sole really practical method on the marketing
today to support die casting design
– High-End technology to provide really virtual result in very
short time (i.e. 30min to 1.5 hour)
– Start from CAD or STL, auto repair and healing
– No requirement for any CAE knowledge, easy learning
Authorised Distributor: Auto-Design-Online www.auto-design-online.com 7
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What Cast-Designer CPI can do?
Thanks Cast-Designer to provide a
fast and flexible way in die casting
for gating system design, but I still
have another question…

Which one is the
best design?

1 2 3
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Cast-Designer CPI: Filling Process

Design plan A: Model Size Elements: 65,364 Nodes: 86,413 CPU: 1,708 Sec

Design plan B: Model Size Elements: 60,343 Nodes: 79,962 CPU: 1,495 Sec

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Cast-Designer CPI: Filling Process

Design plan A: Model Size Elements: 65,364 Nodes: 86,413 CPU: 1,708 Sec

Design plan B: Model Size Elements: 60,343 Nodes: 79,962 CPU: 1,495 Sec

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Cast-Designer CPI: Solidification Process

Design plan A: Model Size Elements: 65,364 Nodes: 86,413 CPU: 464 Sec

Design plan B: Model Size Elements: 60,343 Nodes: 79,962 CPU: 498 Sec
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Ease of Use vs Express Upfront Analysis

Ease of Use
ProCAST

Advance FLOW3D
MAGMA

CAST ANYCAST
Middle
ENGINEER

NOVACAST

CAST-DESIGNER CAE Simulation
Upfront Analysis
Easy
CPI

Time
2 Hours 1 day 3 days

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Ease of Use vs Capability Dilemma
Ease of Use CAE Simulation
Upfront Analysis

Designers

Traditional
CAE
Die design CAST-DESIGNER
Engineers Software
Trade-off
CPI
CAST
NOVACAST ENGINEER
Hardcore/
Full-time
ANYCAST ProCAST
CAE Specialists
(often Ph.D.)
MAGMA Capability
FLOW3D
Unrealistic 80% of Real Special
Simplifications Development Complexities
Situations

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Applications for Cast-Designer CPI
• Aerospace • Heavy Industry/Equipment
– Door, Casings – Tools
– Gas Turbine – Body
– Jet Engine – Food
– Helicopter engine – Pipeline
– Compressors etc. • Railway/Marine/Energy
• Automotive – Engine
– BIW – Goods
– Suspension, Wheel – Wind Energy
– Power train – Brake systems
– Gear – Road
– Exhaust system • Consumer/Manufactured goods
• Computer & Electronics – Watch, Jewelry
– Cover – Medical
– Connector – Kitchen
– Heat – Sinks & Accessories
– Cover

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Cast-Designer CPI Technology Platform

Design CAD
Communications Connection

Design Mesh
Review Product & Die Generation
Development Team Tool

Simulation Simulation
Speed Scope

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CAD Connection
• Standalone system or direct integration with
MCAD geometry kernel
• Parametric and topological associability
Design CAD
• No translation or re-building of model in
Cast-Designer CPI
• No limits on complexity, size, assemblies etc
• One modeling environment

Design Mesh

Speed Scope

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Design CAD

Mesh Generation
• Fast automatic meshing even on large and
Design complex assembly models Mesh
• Flexible mesh sizing, preview
Review Product• & Die treatment forGenerationand feature
Special thinning wall
Development Intelligent mesh enhancement and optimization
• Team Tool

Speed Scope

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Design CAD

Design Mesh

Simulation Scope
Simulation • Full physics to address most fluid and thermal
Simulation
analysis requirements in gating system and
Speed Scope
mould development
• innovation technology for fluid, thermal
solvers with a very fast speed
• Integrates with Cast-Engineer simulation
environments for a more accurate result

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Design CAD

Design Mesh

Simulation Speed
• Computational efficiency
Simulation
• Simulation engine built to solve tough Simulation
problems fast on PC Speed Scope
• Half to one hour for general cases, one day
solve everything
• Uses parallel computing technology for big
and huge model

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Design CAD

Design Review
Design
• Dynamic & interactive – not static Mesh
• Rich result for detail information
Review Generation
• Product knowledge – not just data points
Product & Die
• comparison of multiple versions Development Team Tool
of a design

Speed Scope

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Design Communications
• 3D movie creation with FREE viewer software
• Interactive 3D documentation can be published
Design CAD
within Web pages, PowerPoint, Word, etc.
Communications
• Open result format for internet communication Connection
• No MCAD experience required to interact with
simulation results

Design Mesh

Speed Scope

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Cast-Designer CPI Work process (Standalone)
Gating Voxel Casting Analysis &
CAD Data
System meshing Setup Result
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1 2

• Start from 3D casting, support almost CAD system, such as • Using Cast-Designer to design 3D gating system, overflow and
Catia, UG, Pro-E, Solidworks and AutoCAD venting system
• Standard CAD import and export: STEP, IGES, BREP, DXF, STL • Expert system for high pressure die casting with industrial
• Extra converter to support Catia, UG, Pro-E, Solidworks data validation widely
directly • Natural design workflow, full parameter control, flexible,
• Support many CAE mesh format (STL, UNV, Ansys, Nastran etc.) powerful and easily
• Build in OpenCASCADE CAD kernel with 3D capability • Build in industrial knowledge, experience and know-how
• Powerful CAD clean, healing & processing functions • Support data template and customized template
• Both cold chamber and hot chamber, shot machine selection

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Cast-Designer CPI Work process (in MCAD)
CAD Data
1 2

2

Cast-Designer for MCAD

• Start from 3D casting, using existed CAD system, such as Catia, • Using Cast-Designer to design 3D gating system, overflow and
UG, Pro-E, Solidworks etc. venting system
• Standard CAD import and export: STEP, IGES, DXF, STL etc. • Expert system for high pressure die casting with industrial
• Extra converter to support Catia, UG, Pro-E, Solidworks data validation widely
directly • Natural design workflow, full parameter control, flexible,
• Cast-Designer could be used as option to speed gating system powerful and easily
design as well as build in the same design environment • Build in industrial knowledge, experience and know-how
• Support data template and customized template
• Both cold chamber and hot chamber, shot machine selection

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Cast-Designer CPI Work process
CAD Data
3 4
3
4

• Fully automatically voxel meshing, no CAE knowledge required • Setup casting process, boundary condition and
• Very fast and robust, flexible control the voxel size in different control parameters for CPI analysis
direction • Single page for all condition and parameters, very
• Support multi domain, no Boolean operation required of CAD before simple
voxel meshing • Rich material data, select material from database
• Original data could be CAD or mesh or mixed CAD and mesh directly and database management
• Special treatment for CAD or mesh defects, such as geometry gap, • All conditions and parameters could be save as
overlay, intersection or unclose. CSF template and use back anytime
• Special treatment for tin dimension region to avoid huge model or • No requirement for CAE knowledge, very short
feature lose. leaning curve

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Cast-Designer CPI Work process
Gating Volex Casting Analysis &
CAD Data
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5

• Perform simulation and result analysis
• High-end technology with very fast simulation speed, tens minutes to one
hour depend the model size
• Batch simulation mode and multi tasks could be controlled easily
• Using ParaView as post-processors, very powerful, flexible and without
limitation
• Rich analysis result in various format, support animation and VRML
• Support plug-in filter for post-process, similar concept as Photoshop

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Why not tradition numerical simulation?

Start point Modeling time Analysis time Result accuracy

Perfect CAD geometry Longer! Longer! Relatively high level
with gating system, CAD clean and Hours to days job. accuracy if the
CAE overflow, cooling meshing is a hard work! model was setup
system and mould Need a lots of data for correctly.
modeling. Some trial is
requirement for a
At concept stage, such data is not available usually. good result.

Same environment as A few minutes for any Very fast. Reasonable result
casting and mould model whatever the Half hour to one with very robust.
CPI design, geometry is clean or hour depend the It is accurate enough
Cast-designer could be not. model size. for concept design
used as an option to Setup can be done and plan selection.
speed gating system within two minutes
design. with a few clicks.
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Operation time of Cast-Designer CPI

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CAST-DESIGNER CPI – Demo Case
Model Information

Automotive Part:
Automotive Part: Oil panel
Courtesy: Hongtu tech.
Model Size
Elements: 102,265
Nodes: 151,318
Casting Material: ADC12
CPU Time:
Filling: 4,357 Sec
Thermal: 1,245 Sec

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Metal Flow: Filling Simulation

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Solidification: Liquid Spot, Fluid factor, Temperature, Porosity

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More result for metal flow & solidification

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CAST-DESIGNER CPI
Demo Case

Model Information

Automotive Part:
3C Part, Notebook Casing
Courtesy: Undisclose
Model Size
Elements: 192,452
Nodes: 129,828
Casting Material: AZ91D
CPU Time:
Filling: 4,144 Sec
Thermal: 1,279 Sec

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CAST-DESIGNER CPI
Demo Case

Model Information

Automotive Part:
3C Part, Mobile phone casing
Courtesy: Meijin die casting
Model Size
Elements: 112,249
Nodes: 148,511
Casting Material: AZ91D
CPU Time:
Filling: 4,683 Sec
Thermal: 1,385 Sec

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CAST-DESIGNER CPI
Demo Case

Model Information

Automotive Part:
Communication Part
Courtesy: Undisclose
Model Size
Elements: 150,526
Nodes: 212,131
Casting Material: AlSi12CuNi
CPU Time:
Filling: 7,743 Sec
Thermal: 1,816 Sec

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Air Entrapement

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CPI Analysis helps make decision

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CAST-DESIGNER CPI
Demo Case

Model Information

Automotive Part:
Automotive Part
Courtesy: Dongfeng Motor
Model Size
Elements: 90,229
Nodes: 63,636
Casting Material: Al356
CPU Time:
Filling: 2,768 Sec
Thermal: 812 Sec

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Full Chain of Cast-Designer and CPI

Concept Design Express Validation

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Validation (MCWASP)

T=0.24s

University of Birmingham J. Campbell,
B. Sirrell, M. Holliday

T=0.50s

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Validation (MCWASP)

T=0.50s T=1.24s

T=0.74s T=1.50s

T=1.00s T=1.74s
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Validation (Aalen, Germany)

T= 2.94 ms T= 5.88 ms
The experiment was performed by Dr.
Markus Schmid at ARGE Metallguss in
Aalen, Germany

Filling process of circular casting
with a core
Upper: experimental results
Below: computational results in CPI
T: filling time
Media: Water Velocity: 18.6 m/s
Thickness: 2mm CPU time: 5 min
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Validation (Aalen, Germany)

T= 11.76 ms T= 13.32 ms
T= 10.29ms

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Industrial Validation
• A demo part was existed with
gating system and overflows
• Setup a gating and overflow
system in Cast-Designer in 15
min. based on 3D part
• Parameters of gating system is
parameterized and all data can
be used in later.

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Shrinkage Porosity

Liquid Spots with section line

Section Plan

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Shrinkage Porosity

Liquid Spots with section line

Section Plan

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Validate: Cast-Designer CPI vs Cast-Engineer

Cast-Designer
CPI

Cast-Engineer

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Other Validation – Automotive Products

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Other Validation – Machining Products

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Other Validation – Consumer Products

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Other Validation –3C Products

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Conclusion
• CPI is an powerful tool to simulate the filling process and predict
fill pattern in an express way
• CPI helps user to ‘make decision’ and select the best design, the
whole cycle from design to result can be controlled within one
hour
• CPI is very easy to use and very short learning curve
• The result accuracy of CPI is good enough for concept design and
gating system plan, a fine mesh can help better result
• Developed and validated with industrial partners
– AMCAN, Chicago White Metal, Citation Corporation, Ford-Rawsonville Plant,
General Die Casters, Inc., General Motors Powertrain, North American Die
Casting Association, Ohio State University, R&S Design, Ryobi Die Casting
(USA), Inc.

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Contact

THANK YOU!

For any further query please contact us
Email: info@auto-design-online.com
SKYPE: autodesignonline
Web: www.auto-design-online.com

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C3P Casting Simulation Software

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