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Casting Simulation System ADSTEFAN

Hitachi

One of ADSTEFAN features are "EASY TO USE." However, some skills and know-how are required to set appropriate parameters such as material properties, but also to assess the simulation results. For example, ADSTEFAN users have to put appropriate parameters in order to find countermeasures for casting defects or designings.
Therefore, various types of simulation cases are disclosed on the ADSTEFAN Users' Homepage as "Simulation 100."
Users (with Maintenance support service) are able to find hints for their analysis from the Simulation 100.

Simulation 100 is composed from about 100 cases of simulation(some are in preparation). The cases are classified by casting methods, such as diecasting or gravity casting. Also, the same models are calculated changing its mesh width, injection speed, gating system and so on.
Each case provide its analysis conditions, assessment of the results, analysis time or defect assessment, etc.

Some cases from Simulation 100 are introduced below. All cases are available for only ADSTEFAN users.
Please go to ADSTEFAN Users' Homepage if you are ADSTEFAN Users with maintenance support service.

Excerpt from Simulation 100

Excerpt from Simulation 100
No Case Purpose Model Casting Method Case No
1 The examination of the overflow position Finding the best position of overflows due to gating system change Automotive component: Air control body Diecasting Case1
2 Molten metal behavior evaluation in the sleeve Evaluating behavior of molten metal in the plunger due to difference of plunger speed Automotive component: Air control body Diecasting Case2
3 Finding the reason of the defect Considering defect cause by comparing actual product and analysis results (shrinkage cavity and air entrapment) Automotive component: Bracket for power generation Diecasting Only for Users
4 Analysis for changing plan Modifying complicated design to simple one Automotive component: Air control body Diecasting Only for Users
5 Finding the cause of the defect Considering defect cause by comparing actual product and short shots Cell phone Thixomolding Case3
6 Assessment of Air Exhaust in Cavity Evaluating air exhaust methods in the cavity Test model Diecasting Only for Users
7 The examination of the effect of chiller and riser Considering degrees of influence on shrinkage cavity by chillers or risers Cast iron gear Gravity Casting Only for Users
8 Influence on product by the size of the riser Considering degrees of influence by difference sizes of risers T-shape steel Gravity Casting Case4
9 The influence of riser connection shape to the product Considering degrees of influence on the product by connection geometry Trial casting Gravity Casting Only for Users

CASE1 Examination of Overflow position

Repeat "Design --> Simulation -> Design Change" process in order to find the optimum desgining by taking advantage of one of ADSTEFAN features, "High speed analysis." In this case, Fluid flow analysis is conducted on the initial designing due to find optimum overflow positions. From the simulation results, parts filled in last with reminding air are confirmed. (9,300,000 elements: 2.5hr)

Analysis model : control body

Initial Designing
Initial Designing

2nd Designing
2nd Designing

Simulation result of Fluid flow analysis : Reminding air

Initial Designing
AVI file
Evaluation of the simulation result : Situation of the reminding air when injection is completed. (Blue shows the reminding air)
* At least 4 overflows (shown in red arrow) are required.
Filling is not adequate at the left side. (AVI file)

2nd Designing
AVI file
Evaluation of the simulation result : Situation of the reminding air when injection is completed. (Blue shows the reminding air)
* Overflows are still required at the same positions but
filling at the left side is improved. (AVI file)

CASE2 Molten metal behavior evaluation in the sleeve

Metal behavior in sleeve and air entrapment in cavity due to plunger speed are simulated. Air entrapment and its movement are calculated in about 6 hours (38,700,000elements: 6.2hour)

Sleeve analysis result: Reminding air

High speed (Constant: 180cm/s)
AVI file
Evaluation of simulation result : Situation of the reminding air when injection is completed. (Blue shows the reminding air)
* When injection speed is high speed in constant, Air is entrapped in the sleeve (Red circle part). There is a possibility that the trapped air has bad influence on the products (AVI file).

Medium-High speed (80cm/s => 180cm/s)
AVI file
Evaluation of simulation result : Situation of the reminding air when injection is completed. (Blue shows the reminding air)
* When injection speed is medium - High, air entrapment is improved (Red circle part). (AVI file)

CASE 3 Finding the cause of the defect (Considering defect cause by comparing actual product and short shots)

In order to prove the reliability of ADSTEFAN, defects occurred in the prototype are investigated by Fluid flow analysis with corporate with the collaboration of Hitachi Research Laboratory and Universities.
From this simulation, not only the causes of defects but also ADSTEFAN accuracy is verified. (25,800,000elements: 1.5hr)

Misrun of initial forming

Misrun of initial forming

Fluid flow analysis result: Temperature distribution of molten metal

AVI file

The defect is found at the places where the molten metal collides and air is tropped.This is also the place where temperaturer of molten metal drops sharply. (AVI file)

Analysis: Cold shut defect

Analysis: Cold shut defect

Analysis: Temperature distribution of molten metal

AVI file

Evaluation of simulation results: Temperature distribution of molten metal
* Cold shut defect parts are matched with simulation results which shows temperature drop sharply and air entrapment. (AVI file)

CASE 4 Influence of the size of the riser

In order to prove the reliability of ADSTEFAN, defects occurred in the prototype are investigated by Solidification analysis with corporate with the collaboration of Hitachi Research Laboratory and Universities.
This simulation it to verify how the riser size influences on the shrinkage cavity and to find the optimum size of riser. (1,200,000 elements: 02hr)

Prototype Analysis results: Shrinkage prediction
Riser 120mm Riser 120mm AVI file
Riser 160mm Riser 160mm AVI file

Evaluation of simulation results: Shrinkage prediction

  1. In case of 120mm of riser, shrinkage cavity is found in both riser and product part. In case of 160mm, shrinkage cavity is found only on the riser which is confirmed by simulation results. (AVI file)
  2. In other words, 160mm width of riser is required to produce no defect product. Also, simulation result is matched with the actual defect. (AVI file)