top

Casting Simulation System ADSTEFAN

Hitachi

Introduction

Many products are made by casting (e.g. Diecasting), and its quality and precisions are asked higher and higher. In general, castings are produced relying on casting engineers' skill, experience and intuition.
Therefore, casting engineers spend a lot of time and cost in not only designing but also modifying.

Casting Simulation System, ADSTEFAN visualize physical phenomena occurs in a Mold when molten metal is filling or solidifying.
You can predict what types of phenomenon or defects occurs inside of the Mold without trial casting.
ADSTEFAN brings you to reduce trial casting, designing time and cost, and also to improve quality of a product.

Introduction

ADSTEFAN's HISTORY

Year(Ver.) Enhanced Function
1999(Ver.3.0) Releasement of ADSTEAN
2001(Ver.5.0) Fluid Flow Analysis including Sleeve Area, Tilt Casting Analysis
2002(Ver.5.1) Thermal Stress Analysis, Shrinkage Analysis
2003(Ver.6.0) Temperature Dependency, Time Dependency
2004(Ver.7.0) Expansion Analysis by Graphitization, Tracing of Oxide
2005(Ver.7.5) Difference Correction in Fluid Flow, Gas-Liquid Analysis
2006(Ver.8.0) Parallel Computation, Centrifugal Casting Analysis
2007(Ver.9.0) Microstructure Prediction Analysis, Difference Correction in Solidifiation
2008(Ver.10) Hear Treatment Analysis, Continuous Casting Analysis
2009(Ver.11) Blended Element Method, Surface Tension
2010(Ver.12) Floating License, Fast Fluid Flow Analysis by MPI
2011(Ver.2011) Unification of GUI, Local Pressure, Displaying by Gate-color Code
2012(Ver.2012) Temperature Data Mapping, Intensificatoin Analysis, Condidering Additional Feeding
2013(Ver.2013) Prediction of Micro Porosity, Parting Agent Spray, Material Property's Dependency on Temperature
2014(Ver.2014) Calculation Tool by User, Animation Creation by Batch Processing, Reporting Module, High Pressure for Vaccum Diecasting
2015(Ver.2015) Help Guidance, JMatPro Interface, Shrinkage Calculation in Fluid Flow Process
2016(Ver.2016) High Accuracy in Fluid Flow, Calibration of Material Properties, Linkage with SolidWorks
2017(Ver.2017) High Accuracy of Temperature Analysis in Each Solver, X-ray CT Imaging Data Mapping Tool, Revision of License Management Policy

HIGH SPEED

ADSTEFAN is the fastest casting simulation system operates on Windows.
This is an example of ADSTEFAN calculation time of Basic analysis: Fluid flow analysis and Solidification analysis, with a windows machine (Main memory: 4GB, Clock:2.6GHz).

1. Comparison of Fluid flow analysis

  • Approximately 2 hrs in case total numbers of mesh elements are less than 10,000,000.
  • Approximately 4hrs for 20,000,000 mesh elements.
  • Approximately 14hrs for 50,000,000 mesh elements or over.

expansion
expansion

2. Comparison of Solidification analysis

  • Approximately 1hr (about 50% of time for Fluid flow analysis)

expansion
expansion

USER-FRIENDLY

1. Auto mesh generation (High accurate auto modification function is now available)

FDM (Finite difference Method) Mesh is automatically generated.
Even if a quality of 3D CAD data (STL) is bad, i.e. missing some surface, ADSTEFAN mesh program automatically modifies CAD data errors and reduce time to generate and modify mesh data.

Example of auto mesh modification
Example of auto mesh modification

2. Material Database

  • ADSTEFAN provides material database as standard.Initial value for each material is prepared in the database so that required material database is available by clicking the name of the material. Also, it is easy to customize the database as you want, such as adding new material data or changing some value of the existing material.
  • Wall resistance or temperature dependency data can be registered on the database.
Material Database
Material Types Examples
Casting AI 42 AC4C, ADC12, etc.
Fe, Steel 34 FC, FCD, etc.
Cu 9 BC1, BC2, etc.
Mg 14 AM60, AZ91D, etc.
Ni 1 Inconel
Pb 2 Pb, etc.
Zn 5 ZDC1, ZDC2, etc.
Mold, the others 65 SKD61, chiller, isothermal, etc.
TOTAL 172  

Items of Material properties

3. Import parameters from the previous analysis and Customize the data

You can import and divert parameters from previous analysis if models are similar. Even if there are some differences, you can change them to appropriate parameters for new analysis. It makes it easy for engineers to set parameters for analysis.

RELIABILITY

1. Comparison with actual defect part on the product and simulation result.

Example 1. Fluid Flow Analysis (Misrun) Throttle Chamber
Simulation results predicts a part of defect.

Pic: Misrun on the right projection.    Simulation result: Metal is not filled completely to the end.
Comparison with actual defect part on the product and simulation result.

Example 2. Fluid Flow Analysis (Cold shut) Mobile phone
Defects occur where molten metal with big temperature drop crashes from both sides and where air is trapped.

Fluid Flow Analysis (Cold shut) Mobile phone

Fluid Flow Analysis (Cold shut) Mobile phone

Example 3. Solidification Analysis (Shrinkage porosity) Test Casting
Positions of shrinkage cavities matches with ones of the simulation results. Directional solidification from product part to riser is prevented because the connection part with a riser is thin and long.Therefore, the shrinkage cavity occurs in the product part.

X-ray picture         Analysis Result: Red parts shows shrinkage cavities.
Solidification Analysis (Shrinkage porosity) Test Casting

2. Partnership and Alliance for the advanced technology

ADSTEFAN is evolutionary system.

  • Promote development of new technology with Universities.
  • Implement new technology developed by the universities into ADSTEFAN.
Partnership and Alliance for the advanced technology
University Field Type Description
Tohoku University Fluid flow analysis Method
  • Study of new generation analysis method (Particle method).
  • Speed up of analysis time for thermal stress analysis with new method.
  • Surface Tension.
Okayama Prefectural University Fluid flow analysis Method/Indicator
  • Study of defective indicator for fluid flow
  • Experiment using with water model
  • Mg Injection molding
  • Fluidity test of Aluminum alloy
Iwate University Solidification analysis Indicator
  • Study of chill prediction of FC material (Gray casting)
  • Experiment of shrinkage cavity of FC material

System requirements

OS and Recommended Hardware

  OS Language
OS,Language Windows7 Professional
Windows7 Professional x64 Edition
Windows10 Pro x86
Windows10 Pro x64
Japanese
English
Chinese
CPU
  • Intel: Processor which adopt the development code,Nehalem
    • Core i7(Max 4 cores per CPU)
    • Xeon 5500s(Multi CPU of Core i7)
  • AMD PhenomⅡ
  • IBM POWER5,etc
memory capacity 2GB or more(32bit)
8GB or more(64bit)
  • *Note:Calculation time tends to be faster with 64bit machine rather than 32bit.
Capacity of hard disk 80GB or more
Others CD-ROM drive device