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NovaFlow&Solid CV - Improved casting quality and strength using casting process simulation efficiently

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  • 1. © NovaCast ABNovaFlow&SolidCVNovaFlow&Solid CV - Improved castingquality and strength using casting processsimulation efficientlyAuthor: Håkan FranssonNovacast Systems ABRonneby, Sweden+46 457465800, info@novacast.se
  • 2. © NovaCast ABNovaFlow&SolidCVABSTRACTNovaFlow&Solid CV can make casting process simulations with much fewer meshelements, enabling much faster simulations. This allows making more variants of aspecific casting layout and considerably optimizes the casting. The technology enablessimulations of virtually any type of casting, even extremely thin-walled or complex. Themeshing method used is Control Volume (CV), which means that the outer shapes of the3D model restrict the elements. The elements are 100 % flexible and can assume anyshape, as well as work properly as fractions of elements. The presentation will cover aspecific casting case where you will see how easily you can check different variants of thesame casting layout. It will show the capabilities of the software and how designers canuse the software to improve casting design.
  • 3. © NovaCast ABPresentation Håkan FranssonNovaFlow&SolidCV• CEO Novacast Systems AB• Product Manager NovaFlow&Solid (more than 11 Years)• 25 years in the foundry business• 5 years practical experience from HPD• 4 years practical experience from Gravity castingPresentation Novacast Systems AB• Swedish company with head office in Ronneby• Develops NovaFlow&Solid since 1994• Develops Metallurgical Process Control for cast iron (ATAS)• Novacast Systems has its origin in “NovaCast AB” founded 1981 byRudolf Sillén• Installations in 50 countries with a total of >800 licenses
  • 4. © NovaCast ABIntroductionNovaFlow&SolidCV• NovaFlow&Solid CV is really fast. Solidification simulations is done in maximum 1 hour but oftenwithin minutes, mouldfilling simulations takes from hours up to 24 hours depending oncomplexity of the simulation.• Automatic meshing = meshing complete within seconds• Simulates Mouldfilling, Solidification and stresses• Simulates all commercial casting methods including all types ofgravity casting, Investment casting, Low Pressure die castingand High pressure die casting.• Simulates all commercial materials such as Gray and DuctileIron, Steels of all kinds, Aluminium, Magnesium, Zinc, Copper-Based allloys and Super Alloys.
  • 5. © NovaCast ABNovaFlow&SolidCVEquations/characteristics• Control volumes are used for exact geometry definition (CV method)• Control volume method combines a structured cubic mesh with fractionalcells that can take any shape in order to describe the casting.• CV method (CVM) is used for solution of heat-mass-transferequations, phase transitions, equations of stressed-strained state and alsofree surface transfer• We take the gravity influence into account during filling and solidification• Temperature-dependent material properties• Taking different technological solutions into account (chills, channels, TEHs)
  • 6. © NovaCast ABNovaFlow&SolidCVEquations/characteristicsPouring TemperatureStart solidification = liqidusSolidified 100 % = solidusCooling down to roomtemperature
  • 7. © NovaCast ABNovaFlow&SolidCVBorder cells describe the surface and cubic cells are used when the cells are not effected by theboundaryControl volume - MeshingOne cell can contain different materials
  • 8. © NovaCast AB• The casting has defects• Design creates hot spots which are hard to feed• Simulation of casting only to determine weak points• Calculating feeders within the software• Simulation of chills and feedersProblem definitionNovaFlow&SolidCV• Cast material: Low alloyed Steel (Liquidus: 1512; Solidus:1477)• Mould material: Furan sand• Sleeve material: Exo_Cal = Exothermic material
  • 9. © NovaCast ABNovaFlow&SolidCVFour different simulation variantsCase 1 – Casting only Case 2 – Casting with feedersCase 3 – Casting with feeders no core Case 4 – Casting with feeders and core
  • 10. © NovaCast ABAnalysisNovaFlow&SolidCV• 500 000 Mesh elements used for calculation• Solidification simulation only• Gravity influence according to steel solidification• Results: temperatures, liquid phase fraction, solidification time and micro and macro shrinkages• Can also calculate SDAS; Brinell hardness and Tensile strength
  • 11. © NovaCast ABNovaFlow&SolidCVLiquid phase fraction - Case 1Case 1 Case 2Case 3 Case 4
  • 12. © NovaCast ABNovaFlow&SolidCVLiquid phase fraction - Case 2Case 1 Case 2Case 3 Case 4
  • 13. © NovaCast ABNovaFlow&SolidCVLiquid phase fraction - Case 3Case 1 Case 2Case 3 Case 4
  • 14. © NovaCast ABNovaFlow&SolidCVLiquid phase fraction - Case 4Case 1 Case 2Case 3 Case 4
  • 15. © NovaCast ABNovaFlow&SolidCVShrinkage prediction of case 1Case 1 Case 2Case 3 Case 4
  • 16. © NovaCast ABNovaFlow&SolidCVShrinkage prediction of case 2Case 1 Case 2Case 3 Case 4
  • 17. © NovaCast ABNovaFlow&SolidCVShrinkage prediction of case 3Case 1 Case 2Case 3 Case 4
  • 18. © NovaCast ABNovaFlow&SolidCVShrinkage prediction of case 4Case 1 Case 2Case 3 Case 4
  • 19. © NovaCast ABCalculating feederNovaFlow&SolidCV
  • 20. © NovaCast ABSDAS = Secondary dendrite arm spacingNovaFlow&SolidCV
  • 21. © NovaCast ABConclusionsNovaFlow&SolidCV• Optimize ýyour casting design• Find the best solution to cast it (Calculate feeders)• Optimize casting yield (Casting weight/total weight)• Avoid problems in production• Reduce costs by optimizing the casting for production• Optimize the strength of the casting (SDAS; STRESS calc...)
  • 22. © NovaCast ABFigures and plotsNovaFlow&SolidCVSimulation results numerical• nnnCase Castingyield %Total Weight SolidificationtimeCalculationtimeNo 1 - 50.00 kg 6.01 minutes 1.5 minutesNo 2 88 % 56.45 kg 24.52 minutes 2 minutesNo 3 79 % 62.89 kg 25.50 minutes 2 minutesNo 4 81 % 61.90 kg 25.50 minutes 2 minutes
  • 23. © NovaCast ABQ & A, Thank youNovaFlow&SolidCV