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Getting started

with QuikCAST
(Sand Casting)

Engineering Simulation for


Industry

Getting Started with QuikCAST

List of CAD Files

Chill.STL

Casting.STL
Exo_Sleeve.STL

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

Getting started with QuikCAST


Import CAD Files (Casting)

Casting CAD geometry has been succefully imported


Give a description of the
encountered problem when
thefiles
problems detected
analysing theAll
CAD
during the analysis have been
automatically fixed

7
8

Define CAD File Unit System


2 Input Study Name

Activate Welding Point Operation


Browse to define
3
5
the Study Location
9 Input Tolerance
(mm) the
Browsevalue
and select
Select New option from the File Menu
casting
YES component
to continue STL file
12 Click
Fixing
10 Activate
Click YES to
casting.STL
continue
13Automatic

11

Click OK
Click OK

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 the CAD (Chills)

Chills have been successfully imported

1 4
Select
Import Option from the File Menu
2 Activate
No problems detected
when
Automatic
Fixing
Browse
and select
the CAD
analysing the Chill geometries file chill.STL

Click OK

Click OK

Click Open to load the new


CAD file in the model Window

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

Getting started with QuikCAST


Import the CAD (Sleeves)

Select Import Option from the File Menu


Sleeves have been successfully imported
Browse and select the CAD file
No problems detected when
2
Activate Automatic Fixing
4
exo_sleeve.STL
analysing the Sleeve geometries

Click
3 OK

Click OK

Click Open to load the new CAD


file in the model Window

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

Getting started with QuikCAST


Automatic CAD Inlet Creation

Switch to Wire&Shaded
Mesh Basic
Shapes Option from the Model Menu
SelectSelect
By extrusion
3 option
display mode to display the
facets
Entity selection must
Extrusion Distance
2 be setInput
to Facet

1 4

5
67

Click Apply
when all
Click Close
the
facets
located
at
The inlet volume has
the
top
have
been
been succefully created
selected

Select Facets located


on the top of the tube
( SHIFT + left
button)
> Extruded geometry is
automatically displayed
for each new selected
facet

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

Getting started with QuikCAST


Automatic CAD Mold Creation

The External mold contour is displayed in red


Select Create Mold Option from the Model Menu

1
Switch to the X- View

2
Adjust the mold maximum limit in the Z direction in
order to fit with the top of the tube

Click Apply

External Mold Definition has been successfully


created

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

Getting started with QuikCAST


Import the CAD (Exothermic Sleeves)

In order to detect/assign volume materials


Select Domain Manager Option from the Model Menu

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

Getting started with QuikCAST


Automatic Volume Detection/Material Assignment

In order to detect/assign volume materials


Select Domain Manager Option from the Model Menu

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

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

6
7

Change
Volume
order
with
10 Alloy
Repeat
theRemove
steps
1Priority
22surface
3 domains
4 the
Click
to
delete
12
Select
Volume
Repeat
the
5
6
7
8
arrows
creating
during
the import and during the
type
to rename
the
11
volumes
steps
Alloy
volumes
first
positions
(
filling
order)
View
Volume to
to assign materials
to
the alloy
automatic
fixingClick
sequence
Mold
volume
(display
last position)
the Volume_001
and
mold
volumes
Activate Sandard DB

11

9 Activate
Activate
SurfacePriority
Domainorder.
panelClick P

Input Volume Domain Name


11 Volume domains have been detected that
need to be renamed and assigned with material
8 Select GGG_40 Material
properties.
from theDomains
material list
New Surface
have been
automatically created because the Create
Contact surface option1has been activated
Activate the Create Contact surface option

1
Select Volume_001 (left
click)

Click 3
5 Start to Start the
Automatic Volume
Click Rename
Click detection
Material

Getting started with QuikCAST


3D Grid/FD Mesh Generation

Activate Simplify Method

Select all the volumes except the


mold volume

Input Mininum Size to fix


global grid cell size

Click Apply to generate the


Grid definition

Click Run to generate the 3D Mesh

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

11

Getting started with QuikCAST


Define Gravity Direction

Select PositiveZ direction and check


Gravity Direction
( displayed
green)from
in the Process Menu
Select
Gravity in
Option
the model window

Click OK

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

12

Getting started with QuikCAST


Start the Model Set-up

Select Input Data Check Model Option from the Process Menu and
the Input Data Check window will appear on the left

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

13

Getting started with QuikCAST


Set-up the Metal Flow

Select Fluid Rate BC ( left click) to set up the initial fluid rate for the filling

Click and Select Add option ( right click) to open the panel definition

Activate Imposed Option

Select Inlet Volume in


the Volume list (left click)

Click OK

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

14

Getting started with QuikCAST

Initialize the Metal Flow

Select Velocity BC ( left click) to initialize fluid flow in the inlet volume

Enter
a Velocity
Value
Click and Select Add option (3right
click)
to open the
panel definition
defined in m/s

Select the Surface domain


that corresponds to the top
of the inlet volume

Click OK

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

15

Getting started with QuikCAST


Set Up the Air flow BCs

1
2

3 Input Sand GF index


Select Permeability BC ( left click) to set-up the air flow inside the casting
4 (Input
Click and Select Add option
rightAverage
click) toMold
openthickness
the panel definition
5

Select the Surface


domain that corresponds
to the interface between
the casting and the mold

Click OK

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

16

Getting started with QuikCAST


Set-Up the Wall Roughness

1
2

Select Surface Roughness BC ( left click) to set-up wall rugosity


3 Input Roughness index
(0.05
for to
Sand
Mold)
Click and Select Add option ( right
click)
open
the panel definition

Select the Surface domain that


corresponds to the interface
between the casting and the
mold

Click OK

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

17

Getting started with QuikCAST


Set-Up the Metal Temperature

1
2

4 Input Metal Pouring


Temperature
Select Temperature BC ( left click)
to set-up the pouring metal temperature
Activate
Click and Select Add option 5
( right
click)Filling
to open/ Deactivate
the panel definition
Solidification

6
7
5

Activate Imposed (
Metal pouring
temperature remains
constant)

Click OK to
validate

Activate Volume Domain List

Select Inlet Volume

Activate Filling / Deactivate


Solidification

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

18

Getting started with QuikCAST


Set-Up the Thermal exchange with the External

1
2

Enter External Ambiant Temperature

Click and Select Add option ( right click) to open the panel definition
2 Enter Emissivity Value

3
4

Activate Filling and Solidification

Select External Mold Surface Domain

Click OK

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

19

Getting started with QuikCAST

Set-Up the Thermal Exchange at the interface Alloy-Mold

1
1
2

Select Contact Resistance BCActivate


to set-up the air flow inside the casting
Filling
2 ( left click)
Click and Select Add option ( right click) to open the panel definition

Enter Thermal Resistance value to adjust


the thermal exchange at the interface
casting/mold

Select the Surface Domain that


describes the interface alloy-mold

Click OK

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

20

Getting started with QuikCAST

Run the Calculations

Select Calculation Start Option from the Calculation Menu

Activate Standard Calculation Option

Enter Air temperature inside the


cavity (cavity is empty)

Enter Mold temperature

Enter Filling and Solidification Stop


Criterias ( Time and Temperature)

Activate None option to run a


standard flow calculation

6
Calculation is running now

Click RUN to start the calculation


> Opens the Monitor Calculation Window

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

21

Getting started with QuikCAST


Post-Processing Metal Temperature (Visual-CAST)

Select Snapshot option from the


Select Open option from the File Menu
Results menu

1
Select Volume to load

Click OK

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

22

Getting started with QuikCAST


Post-Processing Metal Temperature (Visual-CAST)

Select THERMAL in Categories and Temperature in


Results to display the temperature results during the
filling and solidification

Select Update to update the last calculated results

Select Arrows to display the differents states

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

23

Getting started with QuikCAST

Post-Processing Feeding during solidification (VISUAL)

4
1

Enter
Minimum
Cut off Solid pockets
Fractionfeeding,
Value select
To analyse
the mushy+liquid
Solid Fraction Contour

5
2

Cut Offmin
Option
Activate Below
Option

Results are now displayed in the cut-off mode

Click Cut
offback
Icon to
to the
open
the cut-off
Click Contour
to go
Contour
Panel
3
parameter panel

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

24

Getting started with QuikCAST


Post-Processing Porosity (VISUAL)

Select Skrinkage Contour


1Input
Max value for cut-off shrinkage

4
2
5

Activate Above Max option

Click cut-off icon to adjust cut-off value that


Activate
Max
needs toAbove
be used
for option
shrinkage

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

25

Getting started
with QuikCAST
(Sand Casting)

Engineering Simulation for


Industry