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Casting Simulation System ADSTEFAN

Hitachi

Function

ADSTEFAN consists of Pre processor, Solver and Post processor.

Pre processor

Required system for analysis are as follows:

CAD data input

Import 3D CAD data (STL format) to ADSTEFAN, and then mesh data (FDM) is automatically generated.

Auto modification of STL data (Highly accurate, Auto modification function)

Even if a quality of 3D CAD data (STL) is bad, e.g. surface inversion, ADSTEFAN automatically corrects error of STL data. Due to this function, mesh generation time is reduced drastically.

Setting of Initial condition and Analysis condition

ADSTEFAN has a material database which contains over 140 types of material data. Therefore, material properties (initial values) are entered automatically by selecting a material. New material data can be added to the database, but also the existing data can be modified to your appropriate values. Also, Properties of temperature dependency, such as a pattern of latent heat release or dynamic viscosity, can be registered to the database.

Saving Initial condition and Analysis condition

The registered data as initial values can be registered to the database and diverted in another calculation.

Analysis Solver

ADSTEFAN consists of various analysis solvers with high speed calculation. These solvers are available for 32bit, 64bit and parallel calculation which leads to further reduction of calculation time.

Applicable Casting Methods

The following casting methods are applicable to simulation: High/Low Pressure Die casting, Thixomolding, Gravity Casting, Sand Casting, Centrifugal Casting, Continuous Casting, ESR (Electro-Slag Refining Process), Evaporative Pattern Casting Process (Pseudo method), Precise Casting (Lost Wax), Heat treatment.

Defect assessment and Optimum designing

  • Misrun, Cold shut, Flow line, Air entrapment, Gas porosity
  • Shrinkage cavity, Micro porosity, Cold flakes, Hot spot
  • Soldering, Casting distortion, Crack
  • Optimization of positions of overflow and cooling, Optimization of risers position and size, position and geometry. Optimization of runner geometry, Optimization of Gate
  • Considering filling speed, filling temperature and die temperature
  • Considering and optimizing casting tact

Various Solvers

The followings are samples of each casting method.

Casting Method Die Casting Gravity Casting Special Casting*1 Cleaning
Solvers High Pressure Low Pressure Squeeze Sand Casting Gravity Die Casting
Fluid Flow Analysis Basic ○ ○ ○ ○ ○ ○ -
Surface Tension ◎ ◎ ◎ ◎ ◎ ◎ -
Back Pressure ◎ ◎ ◎ ◎ ◎ ◎ -
Sleeve ◎ - ◎ - - - -
Solidification Analysis Basic ○ ○ ○ ○ ○ ○ -
Shrinkage ◎ ◎ ◎ ◎ ◎ ◎ -
Die Temperature Analysis Die Temperature ◎ ◎ ◎ - - - -
CSM Die Temperature ◎ ◎ ◎ - - - -
Thermal Analysis Heat Treatment - - - - - - ○
Thermal Stress - - - - - - ◎
*1
Special Casting: Tilt Casting, Centrifugal Casting, Precise Casting, Evaporative Pattern Casting, Electroslag Refining (ESR) Process
○: Basic ◎: Option

Analysis Results of Each Solver

Each solver outputs the following results which are visualized in Post processor.

Fluid Flow Analysis
  1. Filling status of the molten metal (Distribution of filling ratio, Marker of air entrapment, Vector display of molten metal/air, Tracing of flow Air distribution, Pressure, Vorticity, Amount of passing molten metal)
  2. Temperature Distribution (Temperature distribution of molten metal/mold, Initial temperature of filling metal, maximum heating temperature of die )surface
  3. Filling termination time, Air contact time
  4. Graph display of measuring points (Temperature of casting/die, Pressure, Filling ratio, Velocity)
Solidification Analysis
  1. Shrinkage cavity (Status of solidification process, Niyama criterion, Size/shape of shrinkage)
  2. Temperature Distribution (Temperature distribution of casting/mold, Temperature gradient, Temperature of die surface)
  3. Solidification time (Time of solidification start/end, Transit time of critical solid fraction for metal flow)
  4. Cooling rate, Chill prediction, Estimation of spacing of dendrite (DAS-II) arms
  5. Graph display of measuring points (Temperature of casting/mold)
Die Temperature Analysis
  1. Temperature distribution of casting /die, Temperature gradient, Temperature of die surface)
  2. Status of solidification process, Niyama criterion, Cooling rate
  3. Solidification time (Time of solidification start/end, Transit time of critical solid fraction for metal flow)
  4. Graph display of measuring points (Temperature of casting/mold)
Thermal Stress Analysis
  1. Stress (Principal stress, Mises stress)
  2. Amount of displacement
Macrostructure Prediction
  1. Distribution of solidification macrostructure
  2. Status of solidification process
Continuous Casting
  1. Status of solidification process
  2. Temperature display of casting/mold, graph (temperature)
Electroslag Refining (ESR)
  1. Status of solidification process, Cooling rate, Niyama criterion
  2. Temperature distribution of casting/mold, Graph(temperature), Temperature gradient
Heat Treatment Analysis Temperature distribution of casting, Graph of measuring points (temperature)

Post Processor

Post processor visualizes the result files in 3D.Various display methods are available on the Post processor, such as section surface display or emphasis display by setting scaling values.

  • Fluid Flow Analysis Results: Temperature, Filling ratio, Velocity, Flow rate, Vorticity, Volume of entrapment air, ratio of reminding air, etc…
  • Solidification Analysis Results: Distribution of solidus ratio, Temperature gradient, Corrected temperature gradient, Casting temperature, Die temperature, Cooling rate, Degree of soundness, etc...
  • Display Methods: Marker display, Vector display, Counter line display, Graph display, display of volume of molten metal
  • Generation of animation file

e.g.1 Display of reminding air in the sleeve
click

e.g. Shrinkage prediction in solidification analysis (Degree of soundness)
click

e.g.3 Display of multi cross-section surfaces of die temperature
Display of multi cross-section surfaces of die temperature