cast designer cpi-details

Authorised Distributor: AutoAutoAutoAuto----DesignDesignDesignDesign----OnlineOnlineOnlineOnline www.auto-design-online.com1


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.


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

About Distributor

� AutoAutoAutoAuto----DesignDesignDesignDesign----onlineonlineonlineonline 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.

About Distributor

C3P Engineering Software

International Co., LIMITED

Products:

CAST DESIGNERCAST DESIGNERCAST DESIGNERCAST DESIGNERTMTMTMTM


CAST ENGINEERCAST ENGINEERCAST ENGINEERCAST ENGINEERTMTMTMTM

STAMP ENGINEERSTAMP ENGINEERSTAMP ENGINEERSTAMP ENGINEERTMTMTMTM

STAMP DESIGNERSTAMP DESIGNERSTAMP DESIGNERSTAMP DESIGNERTMTMTMTM

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

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

What Cast-Designer CPI can do?

Which one is the

Thanks Cast-Designer to provide a

fast and flexible way in die casting

for gating system design, but I still

have another question…


best design?

1 2 3

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


Cast-Designer CPI: Filling Process



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

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

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

Ease of Use vs Express Upfront Analysis

Ease of Use

Advance

Middle

ProCAST

MAGMA

FLOW3D

ANYCASTCASTENGINEER


Time

Easy

Middle

2 Hours 3 days1 day

CAST-DESIGNER

CPI

NOVACAST

ENGINEER

CAE Simulation

Upfront Analysis

Ease of Use vs Capability Dilemma

Ease of Use

Designers

Die design Engineers

Traditional CAE Software Trade-off

CAST-DESIGNER

CAE Simulation

Upfront Analysis

13Authorised Distributor: AutoAutoAutoAuto----DesignDesignDesignDesign----OnlineOnlineOnlineOnline www.auto-design-online.com

13

Capability

Hardcore/ Full-time CAE Specialists (often Ph.D.)

UnrealisticSimplifications

Special Complexities

80% of Real Development Situations

Trade-offCPI

ProCAST

MAGMA FLOW3D

ANYCAST

NOVACASTCAST

ENGINEER

Applications for Cast-Designer CPI

• Aerospace– Door, Casings– Gas Turbine– Jet Engine– Helicopter engine– Compressors etc.

• Automotive– BIW

• Heavy Industry/Equipment– Tools– Body– Food– Pipeline

• Railway/Marine/Energy– Engine– Goods


14

– BIW– Suspension, Wheel– Power train– Gear– Exhaust system

• Computer & Electronics– Cover– Connector– Heat– Cover

– Goods– Wind Energy– Brake systems– Road

• Consumer/Manufactured goods– Watch, Jewelry– Medical– Kitchen– Sinks & Accessories

Cast-Designer CPI Technology Platform

DesignCommunications

Design Mesh

CAD Connection


16

Product & Die Development Team Tool

Simulation Speed

DesignReview

Simulation Scope

Mesh Generation


Design Mesh

CAD Connection

CAD Connection• Standalone system or direct integration with MCAD geometry kernel• Parametric and topological associability• No translation or re-building of model inCast-Designer CPI

• No limits on complexity, size, assemblies etc• One modeling environment



17

Simulation Speed

DesignReview

Simulation Scope

Mesh GenerationProduct & Die

Development Team Tool


Design Mesh

CAD Connection

Mesh Generation• Fast automatic meshing even on large andcomplex assembly models



18


Simulation Speed

DesignReview

Simulation Scope

Mesh Generation

complex assembly models• Flexible mesh sizing, preview• Special treatment for thinning wall and feature• Intelligent mesh enhancement and optimization


Design Mesh

CAD Connection



19


Simulation Speed

DesignReview

Simulation Scope

Mesh Generation

Simulation Scope• Full physics to address most fluid and thermal analysis requirements in gating system andmould development

• innovation technology for fluid, thermal solvers with a very fast speed

• Integrates with Cast-Engineer simulation environments for a more accurate result


Design Mesh

CAD Connection



20


Simulation Speed

DesignReview

Simulation Scope

Mesh Generation

Simulation Speed• Computational efficiency• Simulation engine built to solve tough problems fast on PC

• Half to one hour for general cases, one day solve everything• Uses parallel computing technology for big and huge model


Design Mesh

CAD Connection

Design Review• Dynamic & interactive – not static



21


Simulation Speed

DesignReview

Simulation Scope

Mesh Generation

• Dynamic & interactive – not static• Rich result for detail information• Product knowledge – not just data points• comparison of multiple versions of a design


Design Mesh

CAD Connection

Design Communications• 3D movie creation with FREE viewer software• Interactive 3D documentation can be published within Web pages, PowerPoint, Word, etc.

• Open result format for internet communication• No MCAD experience required to interact withsimulation results



22

Simulation Speed

DesignReview

Simulation Scope

Mesh GenerationProduct & Die

Development Team Tool

Cast-Designer CPI Work process (Standalone)

CAD DataGating

System

Voxel

meshing

Casting

Setup

Analysis &

Result

1 2

1 2


• Start from 3D casting, support almost CAD system, such as

Catia, UG, Pro-E, Solidworks and AutoCAD

• Standard CAD import and export: STEP, IGES, BREP, DXF, STL

• Extra converter to support Catia, UG, Pro-E, Solidworks data

directly

• Support many CAE mesh format (STL, UNV, Ansys, Nastran etc.)

• Build in OpenCASCADE CAD kernel with 3D capability

• Powerful CAD clean, healing & processing functions

• Using Cast-Designer to design 3D gating system, overflow and

venting system

• Expert system for high pressure die casting with industrial

validation widely

• Natural design workflow, full parameter control, flexible,

powerful and easily

• Build in industrial knowledge, experience and know-how

• Support data template and customized template

• Both cold chamber and hot chamber, shot machine selection

Cast-Designer CPI Work process (in MCAD)

CAD DataGating

System

Voxel

meshing

Casting

Setup

Analysis &

Result

1 2

2


• Start from 3D casting, using existed CAD system, such as Catia,

UG, Pro-E, Solidworks etc.

• Standard CAD import and export: STEP, IGES, DXF, STL etc.

• Extra converter to support Catia, UG, Pro-E, Solidworks data

directly

• Cast-Designer could be used as option to speed gating system

design as well as build in the same design environment

• Using Cast-Designer to design 3D gating system, overflow and

venting system

• Expert system for high pressure die casting with industrial

validation widely

• Natural design workflow, full parameter control, flexible,

powerful and easily

• Build in industrial knowledge, experience and know-how

• Support data template and customized template

• Both cold chamber and hot chamber, shot machine selection

Cast-Designer for MCAD

Cast-Designer CPI Work process

CAD DataGating

System

Voxel

meshing

Casting

Setup

Analysis &

Result

3

3

4

4


• Fully automatically voxel meshing, no CAE knowledge required

• Very fast and robust, flexible control the voxel size in different

direction

• Support multi domain, no Boolean operation required of CAD before

voxel meshing

• Original data could be CAD or mesh or mixed CAD and mesh

• Special treatment for CAD or mesh defects, such as geometry gap,

overlay, intersection or unclose.

• Special treatment for tin dimension region to avoid huge model or

feature lose.

• Setup casting process, boundary condition and

control parameters for CPI analysis

• Single page for all condition and parameters, very

simple

• Rich material data, select material from database

directly and database management

• All conditions and parameters could be save as

CSF template and use back anytime

• No requirement for CAE knowledge, very short

leaning curve

CAD DataGating

System

Volex

meshing

Casting

Setup

Analysis &

Result

5

5

Cast-Designer CPI Work process


• 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

Why not tradition numerical simulation?

Start point Modeling time Analysis time Result accuracy

Perfect CAD geometry

with gating system,

overflow, cooling

system and mould

CAE

Longer!

CAD clean and

meshing is a hard work!

Need a lots of data for

Longer!

Hours to days job.

Relatively high level

accuracy if the

model was setup

correctly.


system and mould

CPI

Same environment as

casting and mould

design,

Cast-designer could be

used as an option to

speed gating system

design.

At concept stage, such data is not available usually.

Need a lots of data for

modeling.

A few minutes for any

model whatever the

geometry is clean or

not.

Setup can be done

within two minutes

with a few clicks.

correctly.

Some trial is

requirement for a

good result.

Very fast.

Half hour to one

hour depend the

model size.

Reasonable result

with very robust.

It is accurate enough

for concept design

and plan selection.

Operation time of Cast-Designer CPI


Model Information

Automotive Part:Automotive Part: Oil panel

Courtesy: Hongtu tech.Model Size

Elements: 102,265Nodes: 151,318

CAST-DESIGNER CPI – Demo Case


102,265Nodes: 151,318

Casting Material: ADC12CPU Time:

Filling: 4,357 SecThermal: 1,245 Sec

Metal Flow: Filling Simulation


Solidification: Liquid Spot, Fluid factor, Temperature, Porosity


More result for metal flow & solidification


CAST-DESIGNER CPI

Demo Case

Model Information

Automotive Part:



Automotive Part:3C Part, Notebook Casing

Courtesy: UndiscloseModel Size


Casting Material: AZ91DCPU Time:


CAST-DESIGNER CPI

Demo Case

Model Information

Automotive Part:



Automotive Part:3C Part, Mobile phone casingCourtesy: Meijin die castingModel Size


Casting Material: AZ91DCPU Time:


CAST-DESIGNER CPI

Demo Case

Model Information

Automotive Part:



Automotive Part:Communication Part

Courtesy: UndiscloseModel Size


Casting Material: AlSi12CuNiCPU Time:


Air Entrapement


CPI Analysis helps make decision


CAST-DESIGNER CPI

Demo Case

Model Information

Automotive Part:



Automotive Part:Automotive Part

Courtesy: Dongfeng MotorModel Size


Casting Material: Al356CPU Time:

Filling: 2,768 SecThermal: 812 Sec

Full Chain of Cast-Designer and CPI


Concept Design Express Validation

Validation (MCWASP)


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

T=0.24s

T=0.50s

T=0.50s T=1.24s

Validation (MCWASP)


T=0.74s

T=1.00s

T=1.50s

T=1.74s

Validation (Aalen, Germany)


The experiment was performed by Dr. Markus Schmid at ARGE Metallguss in

Aalen, Germany

Filling process of circular casting with a core

Upper: experimental resultsBelow: computational results in CPIT: filling timeMedia: Water Velocity: 18.6 m/sThickness: 2mm CPU time: 5 min

T= 2.94 ms T= 5.88 ms

Validation (Aalen, Germany)


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

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


• Parameters of gating system is

parameterized and all data can

be used in later.

Shrinkage Porosity


Section Plan

Liquid Spots with section line

Validate: Cast-Designer CPI vs Cast-Engineer

Cast-Designer

CPI


Cast-Engineer

Other Validation – Automotive Products


Other Validation – Machining Products


Other Validation – Consumer Products


Other Validation –3C Products


Conclusion

• CPI is an powerful tool to simulate the filling process and predictfill pattern in an express way

• CPI helps user to ‘make decision’ and select the best design, thewhole cycle from design to result can be controlled within onehour

• CPI is very easy to use and very short learning curve

• The result accuracy of CPI is good enough for concept design and


• The result accuracy of CPI is good enough for concept design andgating 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 DieCasting Association, Ohio State University, R&S Design, Ryobi Die Casting(USA), Inc.

THANK YOU!

Contact


For any further query please contact us

Email: [email protected]

SKYPE: autodesignonline

Web: www.auto-design-online.com

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