Five Steps to Optimize Casting and Eliminate Defects

1. #DWwebinar

2. #DWwebinar q  This webinar will be available afterwards at www.designworldonline.com & email q  Slides are available in the Resource Widget q  Q&A at the end of the presentation q  Hashtag for this webinar: #DWwebinar Before We Start

3. #DWwebinar Meet your Speakers MODERATOR FEATURED SPEAKER Martin Solina Product Manager Click2Cast Leslie Langnau Managing Editor Design World FEATURED SPEAKER Pablo Fernandez Mechanical Engineer Click2Cast

6. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Click2Castis a casting process simulation software developed around the concept of USABILTY that allows the user to enhance and optimize their manufactured components avoiding typical casting defects such as air entrapment, porosity, cold shots, etc. thanks to the simple and quick mold filling simulation. Click2Cast offers an innovative user experience allowing the complete simulation to be done in 5 simple steps and through a completely new and user-friendly interface. What is Click2Cast

7. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Click2Cast Advantages •  Early simulation •  Easy-to-use •  Quick iterations •  Limited investment •  Keep know-how in-house Benefits of Click2Cast Fast, Easy, Accurate and Affordable

8. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar •  Where to position the Ingate? •  Where to position Feed and Risers and which size? •  Continuous ingate or fan ingate? •  Where to vent: Overflows •  How to balance: Multicavity mold Click2Cast Helps Answer:

9. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Click2Cast Simulation-Driven Design Software for Casting Click2Cast provides guided process templates for: •  Ingate Definition •  High Pressure Die Casting •  Low Pressure Die Casting •  Gravity Sand Casting •  Gravity Tilt Pouring •  Simulation Results

10. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Ingate Definition Click2Cast allows the user to define the material inlet to the part in two different ways: Automatic or Advanced. When using the Automatic option, you need to select a predesigned ingate, either at the runner or on the part. 1.  Select Automatic, then click on the inlet surface. 2.  To add another ingate, select Add Ingate. 3.  To remove an ingate, select Delete Ingate. By selecting the Advanced ingate definition, you are able to use a virtual ingate. 1.  Select Advanced. 2.  Enter the Height, Width, and Orientation. 3.  Select Add Ingate and click a point on the geometry to position the ingate. Automatic Ingate Virtual Ingate Click2Cast Settings

12. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar High Pressure Die Casting Process High pressure die casting uses a machine to inject molten metal into permanent metal dies under high pressure. It is a good technique for manufacturing complex parts with a high degree of accuracy, particularly lightweight parts with thin walls that require consistent dimensions. The high pressure is needed to fill the mold completely and avoid solidification during the casting process. High pressure die casting utilizes two distinct velocities. The molten metal is first pushed at a low velocity (1st velocity) in order to avoid turbulence and the formation of bubbles. Just before the material enters the mold, the velocity increases (2nd velocity) and the molten metal is injected very quickly into the die assembly to fill it completely. Ladle Molten Metal Casting Mold Piston

13. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar High Pressure Die Casting Process Increase the velocity and the cavity is filled in a fraction of a second Solidification inside of the mold Open mold and remove the casted part 4 5 6 Open Mold The mold is closed and the molten metal is poured into the chamber Piston starts pushing slowly 2 31

14. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar High Pressure Die Casting Setup Click2Cast allows you to set up the entire high pressure die casting process by selecting the 1st phase and 2nd phase velocities of the piston and the phase change point. 1.  Under Process Params, enter the 1st Velocity and 2nd Velocity. 2.  Click the Select Node button and pick a point on the geometry to define when the velocity phase change point. Usually this point should be before the material reaches the part (at the end of the runner). 1st velocity 2nd velocity Select Node

16. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Low Pressure Die Casting Process Low pressure die casting is a metal casting process generally used in situations that require high quality manufacturing. In low pressure casting, molten aluminum is slowly drawn into a metal mold or die through a riser tube while kept under constant and controlled pressure. This process helps avoid oxidation, cold currents, and air inclusions, generally producing excellent surface finish and highly accurate dimensions. However, it is much slower and therefore more costly than high pressure die casting. Moving part Mold Pressure Stalk Metal filling Crucible

17. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Low Pressure Die Casting Process PRESSURE 1 MATERIAL 2 Close the mold and fill the crucible The liquid will reach the mold controlled through increasing pressure 3 4 Maintain Pressure during solidification Open mold and extract the component

18. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Low Pressure Die Casting Setup Click2Cast allows you to easily set up a low pressure die casting process by defining the pressure curve in the furnace. (The pressure curve is a time vs. pressure curve of the metal displacement system.) 1.  Define the Pressure curve under the Process Params. 2.  Enter the vertical Distance between the free surface in the crucible and the mold. Pressure curve in the furnace

20. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Die Casting Process Gravity die casting is a type of permanent mold casting generally used for production of small, simple metal parts such as gears, pistons, and wheels. Because the molten metal is poured into the die and rather than injected, it is similar to gravity sand casting but with a permanent mold, making it a better choice for high production volumes. Gravity die casting generally uses non-ferrous metals such as aluminum, magnesium, and copper alloys, although iron and steel parts can also be cast using graphite die molds. Mold Molten metal Ladle Molten metal Moving Part

21. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Die Casting Process Open the mold Close the mold and pour the material. 1 2 3 4 Wait until the end of the solidification Open the mold and extract the casted part.

22. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Sand Casting Process Sand casting is one of the most common casting processes, as it can be used to produce a variety of parts from simple gears and pulleys to complex components such as automobile engines. The process uses an expendable sand mold to form metal parts called castings, which can be made of nearly any alloy. The metal is melted in a furnace and then poured into the cavity of the sand mold. Once the casting is solidified, the casting is removed from the sand mold. Gravity sand casting has few limits on size, shape, and weight, with low pattern and material costs. However, it is generally less accurate than die casting and has a low production rate due to the destruction of the molds. Molten metal Ladle Sand Mold Core Casting Runner

23. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Die Casting Process Make bottom sand mold 1 2 Make top sand mold 3 4 Casting through the gating system Remove the part from the sand

24. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Die/Sand Casting Setup To set up a gravity die or sand casting process in Click2Cast, select the velocity at the ingate or the filling time. 1.  Under Process Params, select Basic. 2.  Enter either the Ingate Vel. or the Filling Time. Filling Time Ingate Velocity Since this is a manual process in which the operator will pour the material directly into the mold, the velocity should not be greater than 1.5 m/s. Use this option if you have calculated the exact filling time required for your process. Units must be in seconds.

26. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Tilt Pouring Process Gravity tilt pouring is another permanent mold process where the mold is positioned horizontally and is gradually tilted upright during the filling process so it is filled in a controlled manner, with low turbulence and a moderate flow rate. This technique compensates for the effect of free fall at the beginning of the pouring process, and helps to avoid air inclusions.

27. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Gravity Tilt Pouring Setup To simulate gravity tilt pouring: 1)  Select Tilt Pouring under Process Params. 2)  Enter a Rotation time. When selecting the rotation time, you are also setting the total filling time (in seconds). 3)  Enter an Initial angle. The initial angle must be negative (e.g., -90º or -45º). The final position is the actual position of the casting (0º). 4)  To define the rotation, first select the global axis by clicking X, Y, or Z. 5)  Click the Rotation Point button and pick a point on the geometry. Note: Rotation will follow the XYZ coordinate axis order; if you select Y as the axis of rotation, then the rotation will turn Z over X; if you select Z, then X will rotate over Y, etc.

29. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar 1. Open the Geometry 2. Define the Ingate and Mesh 3. Set up the Process Parameters 4. Run the Calculation 5. Analyze the Results Casting Simulation in Five Simple Steps

30. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Casting Simulation in Five Simple Steps 1. Open the Geometry 2. Define the Ingate and Mesh 3. Set up the Process Parameters 4. Run the Calculation 5. Analyze the Results Casting Simulation in Five Simple Steps

34. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Front flow shows the filling material evolution. This visualization gives a preliminary idea of the filling time, and the way the part is filled.. Temperature evolution results shows the evolution of temperatures during filling. This animations helps to better understand the heat lost during the filling. Analyze the Results

35. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Shows the vectors representation of the velocities. Shows the front encounter of material during the filling evolution. Blue color shows the areas where exists the front encounter of material. Shows the last areas to fill the part and his air entrapment during the evolution of filling. Analyze the Results Analyze the Results

36. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Mold erosion shows the areas with velocities exceeding 35 m/s, and with high probability of mold erosion problems during the evolution of filling. Shows the filling time of the different areas of the part. Predict if there are some areas solidified during the filling. Analyze the Results Analyze the Results

37. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Shows the temperature evolution during the solidification. Shows the evolution of the solidification. The material that solidifies will disappear from the animation and liquid material will be represented in red color. Shows the time that takes any area of the part to solidify . Analyze the Results Analyze the Results

38. © 2016 solidThinking, Inc. Proprietary and Confidential. All rights reserved. An Altair Company. #DWwebinar Shows the shrinkage porosity percentage in volume over the total volume of the part. Solidification Modulus (Volume-to-area ratio. To use in the riser designer wizard. Helps to calculate an optimal riser. Introducing the casting modulus (meters) we can calculate the required riser for the part. Analyze the Results Analyze the Results

41. #DWwebinar Questions? MODERATOR FEATURED SPEAKER Martin Solina Product Manager Click2Cast msolina@altair.com Leslie Langnau Managing Editor Design World llangnau@wtwhmedia.com FEATURED SPEAKER Pablo Fernandez Mechanical Engineer Click2Cast ptorne@altair.com

42. #DWwebinar q  This webinar will be available at designworldonline.com & email q  Tweet with hashtag #DWwebinar q  Connect with Design World q  Discuss this on EngineeringExchange.com Don’t Forget!

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