Esi Quick Cast

Getting started with QuikCAST (HPDC / Shot)
Engineering Simulation for Industry
Getting Started with QuikCAST
List of CAD Files
casting.stl
ESI Group Copyright ESI Group, 2008. All rights reserved.
Getting started with QuikCAST
Import CAD Files
Select New option from the File Menu

Import CAD Files (Core)
2 3
Input Study Name Browse to define the Study Location
Click OK

Import CAD Files (Core)
Browse and select the casting_HPDC.STL file
Click Open to load the CAD file in the model Window
Import CAD Files (Casting)
Define CAD File Unit System
( casting_HPDC.STL units is MM)
8 9 11
Click OK
Activate Welding Point Operation Input Tolerance value (mm)
10
Activate Automatic Fixing
Import CAD Files (Casting)
QuikCAST gives a description of the encountered problem when analysing the CAD files
12
Click YES to continue
Import the CAD (Core)
HPDC Al geometry has been successfully imported
Automatic CAD Inlet Creation
Select Mesh Basic Shapes Option from the Model Menu
Select By extrusion option
2
Input Extrusion Distance (Piston Chamber lenght)
10
Switch to Wire&Shaded display mode to display the facets
Entity selection must be set to Facet
5
Select Facets located on the top of the tube ( SHIFT + left button)
Extruded geometry is automaticallydisplayed for each new selected facet
11
Click Close The inlet volume has been succefully created
12
Automatic Volume detection/Material Assignment
In order to detect/assign volume materials select Domain Manager Option from the Model Menu
13
1
Activate the Create Contact surface option
Click Start to Start the Automatic Volume detection
New Surface Domains have been automatically created because the Create Contact surface option has been activated
4 Volume domains have been detected that need to be renamed and assigned with material properties.
2
Click View Volume to display the Volume_001
1
Select Volume_001 (left click)
3
Click Rename
4
Input Volume Domain Name
Select Alloy Volume type
7
Activate Standard DB
5
Click Material
8
Select AlSi9Cu3 Material from the material list
4 5 6 7 8 Repeat the steps to assign names and materials to the other volumes
9 10
Change Volume Priority order with the arrows ( Priority order should be defined according to the Filling order)
Click P to Activate Priority order
11
Switch to Surface Domain panel
12
Click Remove to delete the surface domains created during the import and during the automatic fixing sequence
3D Grid/FD Mesh Generation
Select 3D Grid/Mesh Generation option from the Model menu to generate the Grid
22
3D Grid/FD Mesh Generation
Activate Simplify Method Select all the volumes
Input Mininum Size to fix global grid cell size (unit is meter)
Click Apply to generate the Grid
Click Run to generate the 3D Mesh
23
Define Gravity Direction
Select Gravity Option from the Process Menu
24
Define Gravity Direction
2
Click OK
Select PositiveZ direction and check Gravity Direction ( displayed in green) in the model window
25

Start the Model Set-up
Select Input Data Check from the Process Menu and a window with all available boundary conditions will appear on the left This window is used to manage all Boundary Conditions (BC) that will be applied to the model
26

Set-up the Metal Flow
Select Initial Fluid BC (left click) to set up the initial fluid rate for the filling Click on Add... (right click) to open the panel definition
27
Set-up the Sand Flow
3
Input 40% and select Initial
Click OK
4
Select Piston and Chamber Volumes in the Volume list (left click)
28

Select Piston BC (left click) to set up the Sand Core Blowing pressure
Click on Add... (right click) to open the panel definition
29

Select Mold Material for the piston Material
4 5
Select Velocity Calculator Option to automatically calculate the transition from phase 1 to phase 2.i Input Direction, Max Displacement and Velocity for phase 1 and 2
Select Inlet/Pressure1 surface domain
Click OK
30
Set-up the Wall Flow laws
Select Temperature BC ( left click) to set up the metal injection temperature
31

Select Initial Option
4 5
Input Alloy Material Temperature
Select Filling Option
Select Chamber and piston volume domains
Click OK
32
Set-up the Virtual Mold
Select Implicit Mold BC ( left click) to set up the Virtual Mold Material
33

Input Average Mold Thickness
Select Die Material from the Standard DB list
5 6
Click OK
Select the Surface domains having an interface with the die
34
Set-up the Wall Heat Transfert
Select Die Coating BC ( left click) to set up the Virtual Mold Material
35

Input Average Coating Thickness
Select Coating Material from the Standard DB list
Select the Surface domains where the coating is applied
Click OK
36
Set-up the Output Solver Parameters
Select Output Parameter Option from the Calculation Menu
37
Set-Up the Output Solver Parameters
Activate the Filling Panel
4
Select by Percent (%) and input a value in the Graphics field. ( This will determine the number of states generated during the calculation
Click Close
Select the Variable Contours needed for post-processing
38
Run the Calculation
Select Calculation Start Option from the Calculation Menu
39
Run the Calculation
Activate Standard Calculation Option from the Filling/Solidification Panel
Enter Filling and Solidification Stop Criterias ( Time and/or Percentage of Filling/Solidification)
3 4
Activate High Pressure option
Click RUN to start the calculation This will open automatically the Monitor Calculation Window
40
Run the Calculation
> Calculation is running now
41
Post-Processing (Visual-CAST)
Select Open option from the File Menu
42
Post-Processing (Visual-CAST)
Select *.MCO file in the study directory
2
Click Open
43
Post-Processing Metal Flow (Visual-CAST)
1
Select Volumes to load
Click OK
44
Select Snapshot Option from the Results menu
45
Select THERMAL in Categories and Temperature in Results to display the temperature results during filling
5
If your calculation is still running, click Update to update the last calculated results
Select Arrows to display the differents states
46
Post-Processing Sand Flow Particules (Visual-CAST)
47
Post-Processing Examples (Visual-CAST)
48
Post-Processing Examples (Visual-CAST)
49
Getting started with QuikCAST (HPDC Shot)
Engineering Simulation for Industry

Esi Quick Cast

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Esi Quick Cast

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Getting started with QuikCAST (HPDC / Shot)

Engineering Simulation for Industry

Getting Started with QuikCAST

List of CAD Files

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Import CAD Files

Select New option from the File Menu

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Input Study Name Browse to define the Study Location

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Browse and select the casting_HPDC.STL file

Click Open to load the CAD file in the model Window

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Import CAD Files (Casting)

Define CAD File Unit System

( casting_HPDC.STL units is MM)

Activate Welding Point Operation Input Tolerance value (mm)

Activate Automatic Fixing

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Import CAD Files (Casting)

Click YES to continue

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Import the CAD (Core)

HPDC Al geometry has been successfully imported

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic CAD Inlet Creation

Select Mesh Basic Shapes Option from the Model Menu

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic CAD Inlet Creation

Select By extrusion option

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic CAD Inlet Creation

Switch to Wire&Shaded display mode to display the facets

Entity selection must be set to Facet

Extruded geometry is automaticallydisplayed for each new selected facet

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic CAD Inlet Creation

Click Close The inlet volume has been succefully created

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Click Start to Start the Automatic Volume detection

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Select Alloy Volume type