Cast designer cpi-details

1. 1 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

3. 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 3 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

4. 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. 4 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

5. About Distributor C3P Engineering Software International Co., LIMITED Products: CAST DESIGNERTM CAST ENGINEERTM STAMP DESIGNERTM STAMP ENGINEERTM 5 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

6. 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 6 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

7. 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 Auto-Design-

8. 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 8 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

9. 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 9 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

10. 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 10 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

11. 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 11 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

12. 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 12 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

13. 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 13 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

14. 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 14 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

16. Cast-Designer CPI Technology Platform Design CAD Communications Connection Design Mesh Review Product & Die Generation Development Team Tool Simulation Simulation Speed Scope 16 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

17. Cast-Designer CPI Technology Platform 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 Communications Connection Cast-Designer CPI • No limits on complexity, size, assemblies etc • One modeling environment Design Mesh Review Product & Die Generation Development Team Tool Simulation Simulation Speed Scope 17 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

18. Cast-Designer CPI Technology Platform Design CAD Communications Connection 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 Simulation Simulation Speed Scope 18 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

19. Cast-Designer CPI Technology Platform Design CAD Communications Connection Design Mesh Review Product & Die Generation Development Team Tool 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 19 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

20. Cast-Designer CPI Technology Platform Design CAD Communications Connection Design Mesh Review Product & Die Generation Development Team Tool 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 20 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

21. Cast-Designer CPI Technology Platform Design CAD Communications Connection 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 Simulation Simulation Speed Scope 21 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

22. Cast-Designer CPI Technology Platform 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 Review Product & Die Generation Development Team Tool Simulation Simulation Speed Scope 22 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

23. Cast-Designer CPI Work process (Standalone) Gating Voxel Casting Analysis & CAD Data System meshing Setup Result 1 2 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 23 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

24. Cast-Designer CPI Work process (in MCAD) Gating Voxel Casting Analysis & CAD Data System meshing Setup Result 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 24 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

25. Cast-Designer CPI Work process Gating Voxel Casting Analysis & CAD Data System meshing Setup Result 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 25 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

26. Cast-Designer CPI Work process Gating Volex Casting Analysis & CAD Data System meshing Setup Result 5 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 26 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

27. 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. 27 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

28. Operation time of Cast-Designer CPI 28 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

30. 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 30 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

31. Metal Flow: Filling Simulation 31 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

33. Solidification: Liquid Spot, Fluid factor, Temperature, Porosity 33 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

35. More result for metal flow & solidification 35 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

36. CAST-DESIGNER CPI – Demo Case 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 36 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

39. CAST-DESIGNER CPI – Demo Case 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 39 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

42. CAST-DESIGNER CPI – Demo Case 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 42 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

46. Air Entrapement 46 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

47. CPI Analysis helps make decision 47 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

48. CAST-DESIGNER CPI – Demo Case 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 48 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

49. Full Chain of Cast-Designer and CPI Concept Design Express Validation 49 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

51. Validation (MCWASP) T=0.24s University of Birmingham J. Campbell, B. Sirrell, M. Holliday T=0.50s 51 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

52. Validation (MCWASP) T=0.50s T=1.24s T=0.74s T=1.50s T=1.00s T=1.74s 52 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

53. 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 53 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

54. Validation (Aalen, Germany) T= 11.76 ms T= 13.32 ms T= 10.29ms 54 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

55. 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. 55 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

56. Shrinkage Porosity Liquid Spots with section line Section Plan 56 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

57. Shrinkage Porosity Liquid Spots with section line Section Plan 57 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

58. Validate: Cast-Designer CPI vs Cast-Engineer Cast-Designer CPI Cast-Engineer 58 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

59. Other Validation – Automotive Products 59 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

60. Other Validation – Machining Products 60 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

61. Other Validation – Consumer Products 61 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

62. Other Validation –3C Products 62 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

64. 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. 64 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

65. Contact THANK YOU! For any further query please contact us Email: info@auto-design-online.com SKYPE: autodesignonline Web: www.auto-design-online.com 65 Auto-Design- Authorised Distributor: Auto-Design-Online www.auto-design-online.com

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