Mkt mov 02_cd_presentation_gravity_eng_v02
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Cast-Designer CPI is a new generation FEM simulation tool for casting processes that provides express modeling and quick computing. It analyzes metal filling and solidification processes to accurately evaluate casting system designs in an express and flexible manner. Cast-Designer CPI requires no CAE knowledge and can start directly from CAD or STL files. It uses innovative technology to provide virtual simulation results much faster than traditional CAE methods.
Mkt mov 02_cd_presentation_gravity_eng_v02
- 1. CAST-DESIGNERTM CAST-DESIGNER Upfront design & analysis system for Gravity Casting Process Presentation June 2013 www.c3p-group.com
- 2. CAST-DESIGNERTM What is Cast-Designer ？ Cast-Designer is a useful and powerful system to support designers and engineers make system design and upfront analysis in an express way for casting process. • DFM analysis to support casting part design and manufacturing process design • Expect system for casting system design in tens mins to half hour ； • Special Upfront analysis technology for metal filling and solidification analysis based on the last FEM technology, the lead time is 2 to 3 times faster compared with tradition CAE tools includes modeling and simulation ； • Standalone software system based on Open CASCADE technology or fully integrated to the common MCAD system. • Developed by C3P Software with close collaboration with world top level industrial partners, research institutes and universities.
- 3. CAST-DESIGNERTM • Quality by Design is one of the most misunderstood and misused tools available to industrials. • ~ 5% design lead time to solve at least 80% quality problems. • Quality of productions was not depended on checking, not only depended on the produce process, but also mainly depended on design process. We special focus on ‘Design’ and ‘Designer’ Product Designer • No casting background • Focus the function of the product Casting performance of this product? Geo-Designer
- 4. CAST-DESIGNERTM • Quality by Design is one of the most misunderstood and misused tools available to industrials. • ~ 5% design lead time to solve at least 80% quality problems. • Quality of productions was not depended on checking, not only depended on the produce process, but also mainly depended on design process. We special focus on ‘Design’ and ‘Designer’ Die design Engineer Product Designer • No casting background • Focus the function of the product Casting performance of this product? •Die Designer •Specialists in casting field (process and materials) •No CAE experience Which design is best?
- 5. CAST-DESIGNERTM • Quality by Design is one of the most misunderstood and misused tools available to industrials. • ~ 5% design lead time to solve at least 80% quality problems. • Quality of productions was not depended on checking, not only depended on the produce process, but also mainly depended on design process. We special focus on ‘Design’ and ‘Designer’ CAE Specialists Die design Engineer Product Designer • No casting background • Focus the function of the product Casting performance of this product? •Die Designer •Specialists in casting field (process and materials) •No CAE experience Which design is best? •Practical knowledge in casting technology •Advanced CAD capabilities •Modeling experience •Specialists of CAE
- 6. CAST-DESIGNERTM • Quality by Design is one of the most misunderstood and misused tools available to industrials. • ~ 5% design lead time to solve at least 80% quality problems. • Quality of productions was not depended on checking, not only depended on the produce process, but also mainly depended on design process. We special focus on ‘Design’ and ‘Designer’ CAE Specialists Die design Engineer Product Designer • No casting background • Focus the function of the product Casting performance of this product? •Die Designer •Specialists in casting field (process and materials) •No CAE experience Which design is best? •Practical knowledge in casting technology •Advanced CAD capabilities •Modeling experience •Specialists of CAE Cast-Designer CPI Cast-Designer Basic Geo-Designer
- 7. CAST-DESIGNERTM www.c3p-group.com Phase-I Part Base DFM & Design Tools Geo-Designer Powerful Upfront DFM Tool to support product and manufacturing design
- 8. CAST-DESIGNERTM What is Geo-Designer? (I) • Geo-Designer is a powerful upfront Design for Manufacturing (DFM) tools for designers and manufacturing engineers with innovative technology. • It accelerates the design process for functions, manufacturability, enabling designs to move to production better and faster. • Geo-Designer is powerful, flexible, fast and easy to use and provides savings in downstream costs by quality improvement at the design stage. • Geo-Designer offer a new method to study the part geometry in 3D Iso- surface with flexible transparently, it is similar the x-ray and CT method in industrial. • Geo-Designer can analysis the product thickness, draft angle or undercut and fillet radius. Ray method and the Mass Distribution Index (MDI) are supported for geometry analysis.
- 9. CAST-DESIGNERTM What is Geo-Designer? (II) • Geo-Designer can analysis the heat transfer and distribution for the casting process. The Heat Distribution Index (HDI) analysis is much faster and simple than any numerical simulation method. • Geo-Designer can make slider analysis to support mould design. • Geo-Designer can make ejection force analysis for both value and distribution to support ejection pin design. • Geo-Designer can make core checking and design for gravity casting part.
- 10. CAST-DESIGNERTM Geo-Designer could be used for … Mass distribution Wall thickness Draft Checking Fillet Radius Core checking Cooling rate Riser & Gate Heat distribution Slider Checking Ejection Force Chill Design
- 11. CAST-DESIGNERTM Part Analysis for Gravity Casting Ray thickness of casting part, used for thin wall analysis usually Section cut of thickness and Mass Distribution Index
- 12. CAST-DESIGNERTM Concept of Heat Distribution Index (HDI) AE CB F G In HDI calculation, the system will also consider the heat affection of the around media. For example, heat affection by the same part or the riser for gravity casting, it is also possible to consider the different material and heat type, such as chill to speed up cooling, insulates to keep the heat to cool down slowly. If we check it in MDI, the result of region E should be same as the other side of the plate A, such as the left end or the right end. But for heat transfer, plate B and C must affect the heat distribution of region E, such as the region F and G should be more difficult to cool down. MDI=15 MDI=20HDI=15 HDI=20
- 13. CAST-DESIGNERTM Using HDI for riser design (1) Read in the part geometry in 3D CAD data or STL data.
- 14. CAST-DESIGNERTM Using HDI for riser design (2) Read in the riser, chill and gating system one by one. Assign different material properties to riser, gating, chill and insulator.
- 15. CAST-DESIGNERTM Using HDI for riser design (3) Generate the Geo-Designer model and make HDI analysis. The last picture show the result of HDI =15. the affection of the chill to heat distribution is clear (the red arrow).
- 16. CAST-DESIGNERTM Using HDI for riser design (4) We continue check the HDI in higher value, such as 20, 25, 30 and 35. The region with arrow is high risk for shrinkage porosity after the casting process. So the user can adjust the size and locations of the risers to achieve a better result.
- 17. CAST-DESIGNERTM Application: Geo-Designer for Engine Block Geo-Designer could be used to check the basic information of the part, to guide the product design and provide more detail information for manufacturing process design. The information includes, General thickness of the part Section thickness of the part Part information such as volume, mass, surface area, geometry modules, projection area in X/Y/Z direction Part Checking:
- 18. CAST-DESIGNERTM Geo-Designer for Engine Block: casting checking Geo-Designer provides function for slider checking. The red color region must use slider to help eject the part after casting. This information is very useful for die designer. Slide checking: Core checking: Sand core checking is very important for the complex part, such as engine block. It should be useful to check the weak sections of the core at product design stage.
- 19. CAST-DESIGNERTM Geo-Designer for Engine Block: Riser design Geo-Designer provides a quick analysis of the thicker wall zone and such information could be used for riser & feeder design. Region volume and mass in higher HDI could be used for riser size design after consider the riser effectively.
- 20. CAST-DESIGNERTM Geo-Designer for Engine Block: Riser design Build in riser design functions to provide online riser design capability and check it immediately. Support box, cylinder, cone and ball design. Support STL import for addition fuse and substrate for more complex geometry.
- 21. CAST-DESIGNERTM www.c3p-group.com Phase-II Gating System Designer Cast-Designer Basic Full parametric gating system design to support Gravity casting process
- 22. CAST-DESIGNERTM Turn your design concept to 3D data in a quick way 1 2 It is really hard for me to make a clear decision before I have a detail 3D casting system… No problem! Cast-Designer can do that in a few minutes …
- 23. CAST-DESIGNERTM Cast-Designer for Casting System Design Cast-Designer BASIC is an efficient 3D CAD tools with expert system special for HPDC Expert Power Platform An Expert System for Gravity Casting System design to help designer and engineer make a reasonable casting system in a quick way Designer application Includes riser, feeder, gating system , chill, well and cooling system Standard alone software based on last Open CASCADE technology or fully integrated to common MCAD system, such as Pro-E, UG NX, SolidWorks etc Usage Data Learning The design approach is much faster and simple compared with tradition CAD system and fully parametric Standard and special data exchanger for 3D CAD system and CAE system Short learning curve and enhance company design ability shortly Cast-Designer BASIC is an efficient 3D CAD tools with expert system for Gravity Casting
- 24. CAST-DESIGNERTM Full Simulation (Filling & Solidification) Casting +Riser Simulation Gating System Design Riser/Feeder Design Casting only Simulation 3D Casting Part (STL, 3D CAD) 1 2 34 5 6 Cast-Designer Design & Analysis Process
- 25. CAST-DESIGNERTM Cast-Designer: Riser & Feeder design Riser & Feeder Design Build in wizards or calculators to guide the user swiftly towards the optimized design of a feeding and gating system Riser Design Rule: • Time condition: Solidification • Volume condition: predict the delivered volume of open or blind riser or isothermal sleeve • Distance condition: feeding
- 26. CAST-DESIGNERTM Gating System Design Advisor Casting Design Advisor metal, mass, quality requirement Casting Volume Riser & Feeder Filling Time Inner Gate Help solve the solidification problems Casting alloy, Casting part geometry Nbs, section area (Design finished) Fine turning Sprue runner Runner Speed Up Ratio Nbs & section area, shape parameters Design runner, Nbs & section area Increase ratio of pouring system/Spure: Runner : inner gate
- 27. CAST-DESIGNERTM 1 5 43 2 Cast-Designer: Runner design Gate & Runner Design Build in wizards or online help to guide the user swiftly towards the optimized design • Full casting system design (inner gate, runner, Sprue runner, chill, well, cooling system …) • Very similar interface for all design components • Multi-objects support, Multi-plan support • Full 3D model, support draft design concept • What You See, What You Get work style (WYSWYG) • Flexible coordinate adjustment, flexible objects operation • Data template concept, import and export data template.
- 28. CAST-DESIGNERTM Cast-Designer: Sprue Runner design
- 29. CAST-DESIGNERTM One button design for gravity casting gating system • A new approach for gating system design for gravity casting process. It is very suitable for concept design after get the part. • Based on pre-defined gating system template, more than 20 pre-defined templates inside the software package. • Support CDGL (Cast-Designer Gating System design Language) to expand the gating system template by user • Design lead time can be 5 to 10 times faster than the standard design method in Cast-Designer, and tens times faster than CAD. • The design result by One Button Design could be transferred to the standard design wizard directly, for any modification.
- 30. CAST-DESIGNERTM One button design for gravity casting gating system Pre-defined template in Cast-Designer With a rich gating system library for common gravity casting and investment casting. • Very easy to use, set the first gating system within 5 minutes.
- 31. CAST-DESIGNERTM One button design for gravity casting gating system One button gating system design procedure Full parametric design, very easy to adjust the shape and dimension. • Main parameters to control the major dimension and shape minor parameter to control the details.
- 32. CAST-DESIGNERTM One button design for gravity casting gating system One button gating system design examples Put the concept to design quickly. Possible to do final tuning for detail shape and dimension in Cast-Designer wizard.
- 33. CAST-DESIGNERTM www.c3p-group.com Phase-III CPI Validation Cast-Designer CPI New generation FEM simulation for casting process with express modeling and quick computing
- 34. CAST-DESIGNERTM 1 2 3 Thanks Cast-Designer to provide a fast and flexible way in casting system design, but I still have another question… Which one is the best design? Why Cast-Designer CPI? No problem! Cast-Designer CPI can do that …
- 35. CAST-DESIGNERTM What is Cast-Designer CPI (Casting process insight) Analysis Evaluation Analysis the metal filling and solidification process Provide an accurate, express and flexible method for casting system evaluation, select the ‘right’ design Express Innovation Express part and wall thickness analysis Innovation technology compared with tradition CAE method, upfront analysis, accurate, flexible and no limitation. Cast-Designer CPI is a powerful tool integrated in Cast-Designer system based on the last CAE technology
- 36. CAST-DESIGNERTM What is Cast-Designer CPI (Casting process insight) No requirement for any CAE knowledge, easy learning Start from CAD or STL, auto repairing and healing High-End technology to provide really virtual result in a short time Filling: metal filling process, air entrapment, velocity, vector, pressure Solidification: Temperature, liquid/solid fraction CPI is the sole really practical method on the marketing today to support casting design
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- 40. CAST-DESIGNERTM Time Ease of Use Easy Advance Middle ~2 Hours 2 days1 day CAST-DESIGNER CPI ProCAST MAGMA FLOW3D ANYCAST NOVACAST CAST ENGINEER CAE Simulation Upfront Analysis Ease of Use vs Express Upfront Analysis Start point Modeling time Analysis time Result accuracy
- 41. CAST-DESIGNERTM Cast-Designer CPI Flow Chart CAD Data • 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
- 42. CAST-DESIGNERTM Cast-Designer CPI Flow Chart CAD Data Gate System • Using Cast-Designer to design 3D riser, chills, gating system and cooling system; • Expert system for gravity casting design 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
- 43. CAST-DESIGNERTM Cast-Designer CPI Flow Chart CAD Data Gate System CPI Meshing• 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.
- 44. CAST-DESIGNERTM Cast-Designer CPI Flow Chart CAD Data Gate System CPI Meshing CPI Setup • 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
- 45. CAST-DESIGNERTM Cast-Designer CPI Flow Chart CAD Data Gate System CPI Meshing CPI Setup • 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 Post Result
- 46. CAST-DESIGNERTM Cast-Designer CPI Flow Chart CAD Data Gate System CPI Meshing CPI Setup Cast-Designer CPI Post Result
- 47. CAST-DESIGNERTM Meshing technology in Cast-Designer CPI • Innovation technology for meshing generation • Very simple for operation • With coarse mesh, mesh layer and advance geometry mapping (mesh smoothing) technology • Extremely better for accurate in filling pattern and pouring time Full automatic meshing. All functions has summarized in one windows page. Excellent meshing capability. From CAD to final meshing in 5 min.
- 48. CAST-DESIGNERTM Meshing technology in Cast-Designer CPI Thanks the FEM technology, the Cast- Designer mesh can have a good describe of the CAD geometry special for the curved region. CAD model Enlarge the mesh
- 49. CAST-DESIGNERTM CAD Geometry Advance Mesh Smooth Advance Mesh Technology of Cast-Designer Cast-Engineer Simulation Tradition FDM Meshing Cast-Designer Advance Mesh Smoothing
- 50. CAST-DESIGNERTM CAST-DESIGNER vs Traditional CAD & CAE Traditional CAD + CAE Cast-Designer Preparation the geometry for simulation 3h 10 mins Mesh and Setup the model 2h 15 mins CPU time 10h 1.5h Design #1 1 Day < 2 hours Modify geometry 1h 10 mins Remesh and re-setup 2h 15 mins Re-run the simulation 10h 1.5h Design #2 1 Day < 2 hours Try 4~5 times 5 Days vs 1 Days
- 51. CAST-DESIGNERTM Cast-Designer CPI Demo: Gravity Casting Part Shrinkage porosity Solidification process Part with gating system and riser
- 53. CAST-DESIGNERTM Machining Part: defects analysis (Shrinkage porosity)
- 54. CAST-DESIGNERTM Complex gating system for gravity Casting Casting system design: 35 min CPI Meshing: 15 min 323,100 elements
- 55. CAST-DESIGNERTM Design plan A: Model Size Elements: 20,157 CPU: 605 Sec for filling 702 Sec for all Design plan B: Model Size Elements: 18,928 CPU: 473 Sec for filling 660 Sec for all Cast-Designer Solution Comparison
- 56. CAST-DESIGNERTM Stress and deformation analysis • Mechanical Stress Module: Cast-Designer with mechanical stress and deformation simulation capability. Thanks the FEM base technology, no addition mesh and couple calculation in Cast-Designer, one mesh for everything.
- 57. CAST-DESIGNERTM Stress and deformation analysis Part deformation after casting Cast-Designer provides the detail information of the part deformation and distortion after casting. The system consider both the part and mould of the solidification process. It is full couple of the thermal-flow-stress fields.
- 58. CAST-DESIGNERTM Stress and deformation analysis Part deformation result comparison between the actual measurement and simulation The first line picture was the actual measurement result and the second line was the simulation result.
- 59. CAST-DESIGNERTM Components or Modulus of Cast-Designer Cast-Designer Basic Cast-Designer CPI The full Cast-Designer system includes the following components, which could be a complete solution or selected alone as a sub- system. Cast-Designer Basic Expect system for gating system, overflow system and cooling system design for gravity casting Cast-Designer CPI An Upfront analysis system for metal flow and solidification analysis to support ‘decision make’ of die casting system bases on the last CAE technology in an time economic method Cast-Designer / CPI for MCAD Integrate Cast-Designer / CPI to MCAD system (Pro/E, UG NX, Solidworks etc.) Geo-Designer DFM tools for casting part checking, also with on-live functions for riser and feeder design
- 60. CAST-DESIGNERTM 2004~ 2010SolidWorks 17 ~ NX 7UG NX 2000 ~ WF5Pro-ENGINEER SUPPORT VERSIONSCAD SYSTEM 2004~ 2010SolidWorks 17 ~ NX 7UG NX 2000 ~ WF5Pro-ENGINEER SUPPORT VERSIONSCAD SYSTEM • Cast-Designer build in the existed CAD system • Familiar working environment, save learning time • No data transfer problems. The system handle all the data automatically to avoid data lose • Better integration with design data management capability • Full function as standard software version and widely CAD version support Cast-Designer for MCAD System for Pro/ENGINEER Wildfire for Siemens UG NX For DS SolidWorks
- 61. CAST-DESIGNERTM THANK YOU! C3P Engineering Software International Co., LTD WWW.C3P-GROUP.COM