ADSTEFAN Ver.2016 Tutorial[No.2] Fluid Flow Analysis, Solidification Analysis Back Pressure Calculation without airflow (Die Casting method)

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1 ADSTEFAN Ver.2016 Tutorial[No.2] Fluid Flow Analysis, Solidification Analysis Back Pressure Calculation without airflow (Die Casting method) [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved.

Preface Contents The explanation about the operation of the fluid flow analysis considering Back Pressure (without airflow) for High Pressure Die

2 Preface Contents The explanation about the operation of the fluid flow analysis considering Back Pressure (without airflow) for High Pressure Die casting method. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 1

3 The Flow of ADSTEFAN Tutorial 1. Setting input data Correction of Mesh Analysis Condition Input the project file 2. Executing Analysis Fluid Flow 3. Reviewing Results The Displaying results [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 2

Gravity Direction Inflow Direction [Die Casing Method] Flow Analysis with

4 1-1 The Model for Analysis The model s shape for this tutorial : 1_flow01_fan.stl Set outflow spot of air On the top of overflow area. Gravity Direction Inflow Direction [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 3

1-2 Open the Project File 1 By clicking the button, the window Open Project File will open. File Folder File Folder File Folder File Folder ADSTEFAN Ver.2014.. 2Select Diecast(flow_solid).

5 1-2 Open the Project File 1 By clicking the button, the window Open Project File will open. File Folder File Folder File Folder File Folder ADSTEFAN Ver Select Diecast(flow_solid).apo as [project file name]. 3By clicking the button [open], open the project. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 4

3Input the project name as Diecast_Backpressure_no_air.

6 1-3 Saving the Project File as Other Name 1Click the menu [File]-[Save As]. The window for saving the project opens. 2Set the folder for saving new project. 3Input the project name as Diecast_Backpressure_no_air. 4By clicking the button [OK], the project is saved. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 5

1-4 Setting Mesh at the Outflow of Air(1) In the

pressure without air flow will be executed.

Outflow of air from central area is assumed in

7 1-4 Setting Mesh at the Outflow of Air(1) In the tutorial, the fluid flow analysis considering back pressure without air flow will be executed. For executing the function, set mesh setting at air s outflowing area. Add the mesh for outflowing air on the top of overflow. Before Adding After Adding Add 4.mold and by one layer on the top of overflow. Outflow of air from central area is assumed in calculation. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 6

8 1-5 Setting Mesh at the Outflow of Air(2) At first, by copying the mesh on the top area to the next [Z-X] section, set the new mesh for air s outflow Select the area around breaking line by mouse-drag. By double clicking the displayed area, display only [Z-X] section. 1 Click the tab [Modify]. 2 Click the menu[specific Range Copy]. 3 By clicking the icon, display the [Z-X] section. 4 By using slider bar, display the 180th [Z-X] section(top area in casting). 5 With [Ctrl] key clicking, by clicking & dragging left-mouse button, select the area so that to include all casting elements in the area. Selected area is reflected to the setting in the setting view. 6 Select the following item in setting view. [Copy Parts]:3.casting [Continuous]-[Direction]:+Y -[Number]:1 7 Click the button [apply]. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 7 5

1-6 Setting Mesh at the Outflow of Air(3) 11 14 Modify mesh at three areas. 9 8 8By using slider bar, move to the 181th [Z-X] section.

11By clicking the icon, after selecting the checkbox [Mesh Correction], select the Parts Name as 4.mold.

9 1-6 Setting Mesh at the Outflow of Air(3) Modify mesh at three areas By using slider bar, move to the 181th [Z-X] section. 9By clicking the icon after enlarging casting area, display grid line in mesh area. 10Click the tab menu [Correct]. 11By clicking the icon, after selecting the checkbox [Mesh Correction], select the Parts Name as 4.mold. 12By clicking Left-button of mouse, change from 3.casting to 4.mold. 13By clicking the icon, select the Parts Name as 2.mold. 15By clicking Left-button of mouse, change from 3.casting to 2.mold. 10 By arranging the cursor in displayed area, Displayed area can be expanded or shrunk by rotating the center of mouth. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved

1-7 Setting Analysis Condition 1Click the menu [Analysis Condition] 2In the tutorial, execute only fluid flow analysis, so in the 2nd Analysis, deselect the

10 1-7 Setting Analysis Condition 1Click the menu [Analysis Condition] 2In the tutorial, execute only fluid flow analysis, so in the 2nd Analysis, deselect the checkbox [Analysis Execution]. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 9

2By clicking the top line cell, the window [Material Select] is opened.

11 1-8 Setting Analysis Condition(Material Property) Set Material Property about added Parts(4.mold, 5.mold). 1 Click [Material Property Setting]. 2By clicking the top line cell, the window [Material Select] is opened. 3Select the material as [SKD61_Mold]. 4Click the button [OK]. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 10

1-9 Setting Analysis Condition(Fluid Flow) Set the necessary item for considering the effect of the air s outflow and air entrapment. 1Click the menu [Fluid Flow]. 2[Analysis Item] Select Back Press.

12 1-9 Setting Analysis Condition(Fluid Flow) Set the necessary item for considering the effect of the air s outflow and air entrapment. 1Click the menu [Fluid Flow]. 2[Analysis Item] Select Back Press.(without air flow). The button [Back Press.] is activated, and in Project Explorer the menu [Back Press.] is also activated. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 11

13 1-10 Setting Analysis Condition(Back Pressure)(1) 1Click the menu [Back Press.] in [Analysis Condition] - [Fluid flow]. In setting window of [Back Pressure], the following item are inputted. (1) [Critical Air Volume] (2) [Air Vent] [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 12

1-11 Setting Analysis Condition(Back Pressure)(2) Calculation Time(sec) (1) Critical Air Volume The threshold value for replacing air with molten metal is defined. If selecting the option Back Press.

If the air size is too small, air pressure will be estimated as the abnormal value, so when the air size is below the criteria, the air will be replaced with the molten metal.

14 1-11 Setting Analysis Condition(Back Pressure)(2) Calculation Time(sec) (1) Critical Air Volume The threshold value for replacing air with molten metal is defined. If selecting the option Back Press. (without airflow), the fluid flow analysis will evaluate the entrapped air by calculating the air s pressure and volume. If the air size is too small, air pressure will be estimated as the abnormal value, so when the air size is below the criteria, the air will be replaced with the molten metal. Set the ratio of air volume to casting volume. The smaller the setting value is, the better the accuracy is. but the calculation time will become longer. Default value is 1%. The calculation time Set the value as 0.1. The volume is shown according to the value The setting value(critical Air Volume) [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 13

1-12 Setting Analysis Condition(Back Pressure)(3) (2) Back Pressure between Materials In Parts Name 4.mold, set the following item as follows. [Pressure Ratio]:1 [Gap(cm)]:0.

15 1-12 Setting Analysis Condition(Back Pressure)(3) (2) Back Pressure between Materials In Parts Name 4.mold, set the following item as follows. [Pressure Ratio]:1 [Gap(cm)]:0.01 [Length(cm)]:20 Mold thickness Pressure Ratio : [pressure in outside area]/[pressure in cavity area] Gap (cm) : The setting gap for outflowing air. Length(cm) : The length of outflowing vent Gap of Air vent (Air Outflow) 2.mold 3.casting 4.mold [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 14

1-13 Setting Analysis Condition(Heat Resistance) 1Click the menu [Heat Resistance] in [Analysis Condition] - [Fluid Flow]. 2 The added materials are regarded as the parts of mold.

16 1-13 Setting Analysis Condition(Heat Resistance) 1Click the menu [Heat Resistance] in [Analysis Condition] - [Fluid Flow]. 2 The added materials are regarded as the parts of mold. The setting are as follows. 2.mold/4.mold:(Same Mold) 0 (cm 2 s/cal) 3.casting/4.mold:(Die/Mold) 5 (cm 2 s/cal) [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 15

1-14 Setting Analysis Condition(Results Output) 1Click the menu [Analysis Results Output] in the [Fluid Flow]. 2[Output Files] Select the following items.

17 1-14 Setting Analysis Condition(Results Output) 1Click the menu [Analysis Results Output] in the [Fluid Flow]. 2[Output Files] Select the following items. Gas Volume the residual gas volume(cc/cm 3 ) in molten metal and the graph by gas volume(cc/100g) In the option Back Press.(without air flow), the item will be automatically selected. [Entrapped Air Volume] The Volume of entrapped air in standard pressure. [Max Air Pressure] the maximum of air pressure [Gas Marker] Color coding with the size of entrapped air by generating marker in the air replaced with molten metal. After saving these setting data, execute analysis from the window of Executing Analysis. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 16

18 2-1 Displaying Analysis Results(1) Max Air Volume The possibility of the air entrapment s defect is high in higher pressure area. Air Entrapment Volume The possibility of the air entrapment s defect is high in larger volume area. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 17

19 2-2 Displaying Analysis Results(2) Gas Quantity by the contour The possibility of the air entrapment s defect is high in larger quantity area. Gas Quantity by the graph The quantitative evaluation of gas volume in each part(gate, product, etc.) To evaluate in each parts, define multiple different parts name in advance. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 18

2-3 Displaying Analysis Results(3) Gas Size(before intensifying) The possibility of the air entrapment s defect is high in larger air-size area. The air above diameter 2[mm] is displayed.

20 2-3 Displaying Analysis Results(3) Gas Size(before intensifying) The possibility of the air entrapment s defect is high in larger air-size area. The air above diameter 2[mm] is displayed. Gas Size(after intensifying) In considering the effect of intensification, the result data at final frame shows the status after intensification. [Die Casing Method] Flow Analysis with Back Pressure(no airflow) Hitachi Industry & Control Solutions, Ltd All rights reserved. 19

20 [Die Casing Method] Flow Analysis with Back Pressure(no airflow)

ADSTEFAN Ver.2016 Tutorial [Overview]

ADSTEFAN Ver.2016 Tutorial [Overview] Outline of the Operation Method 0 About the ADSTEFAN ADSTEFAN ADvanced Solidification TEchnology for Foundry Aided by Numerical Simulation ADSTEFAN is initiated by