Cast designer basic

Authorised Distributor: Auto-Design-Online www.auto-design-online.com
Auto-Design-

www.c3p-group.com
Auto-Design-

About C3P-Group
C3P Engineering Software International Co., LIMITED , a pioneer
supplier of CAX solution for industrial manufacturing processes.

With the combination of software development, advanced analysis,
extensive product development experience and cost effective local
human resources, we provide industry and manufacturing business
with comprehensive solutions and engineering services globally.

Our offices are located in New York, San Diego, Hongkong and
Guangzhou.

For any further details please visit www.c3p-group.com


About Distributor
Auto-Design-
Auto-Design-online provides corporate training and engineering
services on latest CAD-CAE software.

Core team has extensive international experience, working closely
with European OEM like BMW, AUDI, IVECO.

Authorised distributor of Stamping & Casting solution developed by
well known C3P Engineering Software International Co. Limited.


About Distributor
C3P Engineering Software
International Co., LIMITED
Products:
CAST DESIGNERTM

CAST ENGINEERTM

STAMP DESIGNERTM

STAMP ENGINEERTM


About Distributor
Application & objectives of C3P simulation Software
Application Objectives
• High/Low pressure die casting • Mold filling animations
• Semi-solid casting • Solidification animations
• Gravity sand & die casting • Solidification times & directions
• Gravity tilt pouring • Shrinkage
• Investment casting • Hot spots
• Continuous casting
• Centrifugal casting
• Liquid stamping and Ladling
operations


CAST-DESIGNER BASIC
An Expert System for High Pressure Die Casting gating
system design to help designer and engineer make a
reasonable die casting system in a quick way
Designer application Includes gating system , overflow,
cooling and venting system
Standard alone software based on last Open
CASCADE technology or fully integrated to common
MCAD system, such as Pro-E, UG NX, SolidWorks etc.
The design approach is much faster and simple
compared with tradition CAD system and fully
parametric
Standard and special data exchanger for 3D CAD
system and CAE system
Short learning curve and enhance company design
ability shortly


Application of CAST-DESIGNER
Help designer and engineer to
make a better casting system
design
Guide by industrial knowledge
database, better quality and more
reasonable
Much faster and simple compared
with tradition CAD tools
Easily modify and update designed
data
Provide an express method to
modify the existed design
As pre-processor of CAE system to
design/re-design the casting
system geometry with fully
parametric


Main Features of CAST-DESIGNER
• Standalone version and • Natural and stream line
integrated version with fully design, i.e. from paper draft
integrated to MCAD system to 2D vector to 3D design;
• Start from 3D casting part in from inner gate, gate-runner
existed solid model (MCAD to runner, sprue-runner and
system) or STEP/IGES/STL absorber;
format (standalone system) • All design of gating,
• Powerful 3D gating system overflow, cooling and
design with natural design venting system in the same
concept, industrial know-how working environment with
and knowledge industrial guide
• Fully parametric design for • Data exchange capability
gating and overflow system with CAD and CAE system
with template support, no • Powerful, flexible, simple
complex F-S relationship and easily to use, very short
compared with CAD system learn curve

Natural Design of Gating in Cast-Designer

1 2 3


Design concept to 3D data in a quick way
It is really hard for me to make a clear
decision before I have a detail 3D casting
system…

No problem! Cast-Designer can
do that in a few minutes …

1 2 3


Cast-Designer & CPI

30 min 1 hour

Cast-Designer Cast-Designer
Basic CPI

15 min
Cast-Designer & CPI
Analysis helps make
Cast-Designer
Basic decision


Cast-Designer & CPI

30 min 1 hour

Basic CPI

1 hour
15 min
Basic CPI

Designer have the opportunity to
15 min complete his design within 8 hours
Cast-Designer
Basic


Make Better Gating System -1

Gating system of Oil Panel.
Designed by 5 years experience engineer.
4 hours in UG NX.



Gating system of Oil Panel.
Designed by 1 years experience engineer.
1/2 hours in Cast-Designer..



Section area was not designed well in the original design.
Casting Zone was not correct in the original design.
Speed ratio was not very well in the original design.


Filling process of different gating system


Casting Design Advisor
Gating System Design Advisor
Casting Volume Fine turning
(metal, mass,
(Design finished)
quality requirement)

Gating & Overflow Sprue runner
(estimate the mass (Nbs & section area
Ratio of casting) Oyher parameters)

Casting machine Gate / Runner
(Design gate runner
(select machine, ton,
and runner, Nbs &
Filling ratio, piston Dia.)
section area)

Speed Up Ratio
Inner Gate (Increase ratio of Spure:
(Nbs, section area) Runner :gate runner
: inner gate)

Casting Zone concept
• It is a very useful method
for multi inner gate design
• The metal flow in all inner
gates should balance, such
as the similar max. flow
distance
• Inner gate area calculated
by the flow mass and
filling time
① ② ③ • Save result as inner gate
④ format.
The image The image The image The image
cannot be cannot be cannot be cannot be
display ed. Your display ed. Your display ed. Your display ed. Your
computer may computer may computer may computer may
not hav e enough not hav e enough not hav e enough not hav e enough
memory to open memory to open memory to open memory to open
the image, or the the image, or the the image, or the the image, or the
image may hav e image may hav e image may hav e image may hav e
been corrupted been corrupted been corrupted been corrupted


Build in Draft Design Concept
• Most effective way to bring out your
design as natural thinking…
• Flexible to discuss with teachers,
colleagues, leads, customers
• Design/Re-design/Modify in free
style
• Internal meeting & web meeting, co-
design in different location
• Suitable to complex part design

• Support many picture formats: JPG,
BMP, TIF etc.
• Raster format as background
• Vector format for snap with
automatic converter from Raster
• Advance adjustment tools for mapping

Streamline Design

Workspace

Draft design
• All functions of casting system design
Gating system were summarized in one toolbar
• Streamline design from the left to
Overflow right or up to down to complete a
design
• Similar user interface to speedup the
Cooling & Venting work affections and reduce learning
curve
Design check • Help new designer have a clear design
image and guide the work

Kernel & User’s Interface of Cast-Designer
• Build in OpenCascade
• Build in OpenCascade
technology, one of
technology, one of
the most famous
the most famous
CAD kernel
CAD kernel
• Module design style
• Module design style
to simple operation
to simple operation
• Powerful 3D CAD
• Powerful 3D CAD
function
function
• Advance 3D solid/
• Advance 3D solid/
surface capability
surface capability
• Full integration of
• Full integration of
CAD/CAE/CAPP
CAD/CAE/CAPP
• Powerful data
• Powerful data
exchanger
exchanger


Kernel & User’s Interface of Cast-Designer
• 3D CAD & Mesh in
the same working
environment
• Advance features
for CAD & Mesh
selection in the
similar way
• Full display control
for both CAD &
Mesh (WF/ Color/
Shade etc.)
• Support a wide range
element types (1D/
2D/ 3D)
• Complete mesh
operation functions
• Many advance mesh
functions for
Authorised Distributor: Auto-Design-Online defined application
www.auto-design-online.com

Cast-Designer for MCAD
• Cast-Designer build
in the existed CAD
system
• Familiar working
environment, save
learning time
• No data transfer
problems. The
system handle all the
data automatically to
avoid data lose
• Better integration
with design data
management
C SYSTEM
AD SU R VER O S
PPO T SI N
capability
Pro-ENGINEER 2000 ~ WF5
• Full function as
UG NX 17 ~ NX 7
standard software
SolidWorks 2004~ 2010 version and widely
CAD version support

Different of standalone & MCAD version

Casting System Couple to Couple to
Start point
Design CPI/CAE CAD/CAM

Existed 3D CAD Same working Very good! OK! But need do
part in STEP/ IGES environment. Same working some fine turning,
STD /STL format. Special designed environment with (Boolean, fillet,
Not recommended technology to full mesh functions. sew, partition etc.)
to design a full speed up the Special technology Some function is
casting from zero, casting system in meshing for time consuming if
repair is possible. design. defects of CAD. the geometry is
complex.
Same as standard A plug in window in Possible, but Very good!
3D CAD software, it MCAD system limited to mesh No data lose and
MCAD is used in industrial also with data function usually. can enjoy all fine
for product & mould management. Except also with turning functions of
design widely with Same interface Cast-Design CPI CAD system, and
a lots of learning and function as for MCAD system sometimes it is
material. standard version. together. more advance.


Full Integrated CAX Environment

• Complete CAD functions from basic • Full range mesh generation &
primitives, Vertex, surface & solid operation functions, include 1D/2D/
generation to CAD transformation, 3D manual-Auto generation, mesh
Boolean operation & Check. transformation & info. check.

Gating System Designer

Overflow
Workspace
shock absorber

Draft design
Inner gate
Gate runner
Gating system
Runner

Overflow
Sprue runner

Cooling & Venting
Piston
Design check


Gating system design procedure
Casting Design Advisor

Inner gate & centre of piston location

Casting-Zone analysis (if any)

Runner, Gate-Runner trace define

Detail parameter define and turning

Overflow, cooling & venting design

Design Check & Evaluation


Cast-Designer Working procedure
The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the
image may hav e been corrupted. Restart y our computer, and then open the file again. If the red x still
appears, y ou may hav e to delete the image and then insert it again.

Work Space / Part plane
Easy to draft, snap, dimension
CAD method or mesh method

Draft Design
Load draft from BMP, JPG, TIF
Convert bitmap to vector
Advance tools for CAD match


Natural draft concept in Cast-Designer

Load in
draft as
background
(Raster
format)


Natural draft concept in Cast-Designer

Load in
draft and
convert
to vector
objects


Gate System Design (General)

• Each design can be assigned
Streamline design process to a project name for data
manage, multi-plans and
multi-versions is possible
• Work plane and location
could be set as general in
one button and also possible
to modify it in separate
• Support gate system
geometry operation to
speed up design (translation,
rotation and symmetry)
• Support gate system
template and data exchange
(save, load, import, export)


Gate System Design (General)

• Choose the type of shot
machine from the data
base
• Choose type of chambers
• Wide data base of the
manufacturer
• According to the machine,
it will automatically
consider the other
required details e.g. piston
dia, ton filling ratio etc.


Gate System Design (Inner Gate)
• Similar interface for all components
• 1 Object list, 2 Data table
• 3 Properties, 4 Coordinates
• 5 Function button
1
• Multi-objects support
• WYSWYG (What You See, What
You Get), both 2D and 3D preview
3 • Flexible coordinate adjusting
• Online tips and area checking
4

2
5


• Inner gate data management
• Quick design transformation
• Translation, Rotation, mirror
• Online tips and section area
checking, velocity vector preview
• Online tens year industrial
experience & know-how to guide
the design
• Filling velocity & filling time
base on casting metal and
wall thickness


• Advance filling time calculator
suggested by NADCA. The filling
time with a high accurate since it
is also consider the quality
requirement of casting products.

• Ingate evaluation to help
design/check inner gate based
on casting metal and geometry,
it is widely approved in real
mould industry.


Online velocity vector preview bases
on simple geometry calculation. It
could be used to,
Inner gate filling angle check
Casting zone check
Unfilled zone check

Since this is a very rough evaluation
it is recommended to have a detail
CPI analysis for detail.


Gate System Design (Gate Runner)

1 • Very Similar interface as inner
gate design
• WYSWYG (What You See, What
You Get), both 2D and 3D preview
3 • Online runner design wizard

4

2 5


• Full parameters for complex design
• User defined trace feature line
• Sections, Start & last angle
• Sections & sweep method, smoothing
or not, automatic connection


Pre-defined gate-runner/runner: Straight sided, curve sided and
tangential. Full parameters control and simple/fast setup.


Complete parameters for WL WR

gate-runner: 2 parameters
for draft angle (DraftL,
O (X,Y, Z)
DraftR), 2 parameters for
D
runner width (WL, WR); Draft Angle L Draft Angle R

Triangle section is possible
depend the input data
(Angles & width).
Flexible adjust tools for
both coordinate and width.


Design Complex Gate Runner Trace

Complex gate runner/runner trace could
be designed by picking pre-defined
curve directly.
Parameters of start & end sections
could be defined in setup wizard.
Section Nbs. Could be assigned by user
as the complex ratio of runner
Multi gate runners could be connected
automatically based on the geometry.


Multi-segments Runner


Powerful runner wizard and runner link


Example: Runner design


Gate System Design (Gate runner)
3D Gate Runner/ Runner Capability

With full capability of 3D gate
runner/ runner design.
One-direction 3D runner (plan in
width direction) could be designed
directly as usual.
Full 3D runner (it is also curved in
width direction) could be designed
as above then use ‘Extrusion’ to
extend up/down surface then cut it
in the parting plane (curved surface)


Gate System Design (Gate runner)
Example for fully 3D Gate Runner design
The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and then insert it The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and then insert it again. The image cannot be display ed. Your computer may not hav e enough memory to open the image, or the image may hav e been corrupted. Restart y our computer, and then open the file again. If the red x still appears, y ou may hav e to delete the image and then insert it again.
again.

Define parting Define the gating ‘Extrusion’ the runner
surface, it is a 3D system as usual and cut it in parting
surface (plan in width direction surface to obtain the
of runner) final design

Gate System Design (Runner design)

• Very Similar interface and design
method as gate runner
• Suitable simple shape and long flow
path (WL=WR)
• Online runner design wizard


Gate System Design (Runner design)

Section Evaluation

Useful tools to check the gate
runner /Runner design, ensure the
design is correct.
Detail information of the section
location, area and increase/
decrease ratio.
Adjust the design/Dimension
immediately and recheck the data
again.


Gate System Design (Cold Chamber)

1

4 Support cold chamber, hot chamber
casting machine and no sprue
runner design.
2 Full parameter for sprue-runner;
Support multi sprue runner design
WYSWYG.
Online evaluation for casting
process and machine selection.

3


Gate System Design (Hot Chamber)

1

4 Support cold chamber, hot chamber
casting machine and no sprue
runner design.
2 Full parameter for sprue-runner;
Support multi sprue runner design
WYSWYG.
Online evaluation for casting
process and machine selection.

3


Gate System Design (Spure Runner)
Plunger Evaluation

Machine
selection

Process
parameter


Gate System Design (shock absorber)

1
Full parameters for absorber;
Support Multi group definition.
WYSWYG.

2


Overflow design (Standard design)
Very effective and flexible way to
design overflow system

1 Standardized, full parametric,
flexible location and rotation
Build in overflow type: rectangular,
orbicular and wedge, pre-defined
data template to speed up definition.
Support multi group overflows with
data management capability
Design data operation (translation,
rotation, mirror, extrusion …)
Overflow data exchange (I/O)
Support customization template
2


Overflow design (Standard design)
• Flexible method for overflow
position and location (fix side or
movable side or both side)
• Design data export and import and
support customized template


Overflow design (Non-Standard design)
• To design non-standard overflow
upon casting geometry or others
• Define base plane profile of
overflow as an edge or wire
• Define the basic overflow
parameters (depth, draft angle and
extrusion direction etc.)
• Define central line of overflow gate
(line, gate width and depth)
• Define the overflow location type
(fix or movable half )


Cooling channel design

Pre-defined centre line for cooling
channel (2D/3D Import or draft in Cast-
Designer)
Flexible 3D lines operation
Section shape and dimension control
Support multi channels and multi section
area definitions, fully parametric design
Automatically CAD Boolean operation
Cooling channel advisor for channel
length & diameter and HTC calculator


Cooling channel design
Cooling Channel Calculator

Cooling channel calculator to
calculate cooling line length and
diameter based on industrial
approval formula
Build in heat transfer coeff.
(HTC) calculator
Mould mass and cooling could be
considered
Heat affection rate could be
considered


Venting channel design

Pre-defined centre line for venting
channel (2D/3D Import or draft in Cast-
Designer)
Section shape and dimension control
Support multi channels and multi section
area definitions, parametric design
Automatically CAD Boolean operation
Support draft angle and partition plane


Venting block design

Venting block design in die casting to
support vacuum system;
Full parameter design ;
Flexible position and location control;
Preview function, WYSWYG
Design date export and import, support
customized template
Link with venting channel easily


Gate System Checking
Section Checking

Filling Ratio

Casting Yield

Shot Checking

Checking the section area in
defined cut direction for any
3D geometry
Define sections number and
distance of each section
This checking is important and
absolutely necessary for
complex geometry, such as
multi-runner with Boolean
operation in different direction

Section Checking

Filling Ratio

Casting Yield
Machine
Shot Checking Selection

Database with more than 200
machines and easily to expend
more by user
Select correct piston diameter
and chamber length to achieve a Process
reasonable filling ratio parameter
Predict the 1st and 2nd speed
to avoid chamber gas problem
Calculate the position and time
for critical accelerate point;
Machine capability evaluation.


Section Checking Casting yield checking to compare with
industrial requirement
Filling Ratio Predict locking force for machine
selection
Evaluate machine capability bases on
Casting Yield
part geometry, casting metal and
product quality requirement
Shot Checking


Cast-Designer result data
• Design data was a set of
solid components assigned
by defined name
• Solid components were
not combined together, it
could be done by user if
necessary
• It is possible and often
for initiation design: CAD
overlay, intersection, tin
gaps … it could be treated
only after the design plan
was confirmed (time
Useful tools for geometry fine turning consuming sometimes )
• Cast-Design provides a
set of tools to combine
CAD Sew Fillet Chamfer Partition Glue the objects and fine
Boolean operation turning the design

Cast-Designer result (Geometry turning)
Prepare data for CPI/CAE Analysis

• Unnecessary to fuse solid components, only
select the ‘Multi domain’ option in fast
meshing
• Make fillet for big dimension which may
affect the metal flow (i.e. sprue runner),
unnecessary for small fillet
Initial design
Prepare data for CAD modeling

• Fuse solid components is necessary usually,
also ask to sew the surface for same surface
• Make fillet is necessary and it is time
consuming some times
• It is always suggest to export the gating,
overflow and cooling system in STEP format
to MCAD system for geometry combine and
Geometry turning
fillet or select Cast-Designer MCAD version.

Cast-Designer Data Exchange

CAD General
CAD General
CAE CAD General
System
CAE System

STEP STL Cast-Engineer STL
IGES DXF Ansys Patran
BREP Pro-CAST Ideas (UNV)
Nastran OFF

CAD Advance CAM System
CAM System
CATIA UG STL
Pro-E SolidWorks
ParaSolid Extra license
required


Export design data to other CAD system
• The design data of Cast-Designer could be exported to other
CAD system in 3D Solid objects directly
• Support export format： STEP, IGES, BREP
• The recommended export formats for gating system are STEP or
BREP, both types file have best geometry quality
• It is recommended to export all components in one STEP file without
Boolean operation
• Notice for exporting Cast-Designer to a sole solid/part CAD
system
– Please select sole solid/part than assembly，then the system will
carry out Boolean operation for all the components automatically and
get a sole part (i.e. PRO-E, CATIA etc.)
– System recognizes all the solids and convert to multi files with one
file one solid, the user need load one of the above file and insert the
others one by one, after that the system will carry out Boolean
operation automatically and get an one sole part (i.e UG NX,
SolidWorks)

Cast-Designer Snapshot

Cooling feature line


Couple Cast-Designer with simulation software

• What CAE can do?
– Bases on Input data, provides output result
– Detail casting process information: metal filling,
solidification, stress etc. What CAE can not do?
– Modify the existed model geometry directly
– Fast modify the existed design plan as CAE result
• Cast-Designer can couple to any CAE system as a pre-
process for casting system design or modification,
whatever FEM or FDM/FVM code.
• Cast-Engineer, MAGMA, Pro-CAST, Flow3D,
AnyCasting, QUICKCAST, NOVACAST, JSCAST …
• Supports STEP/IGES/STL and many mesh formats


Major Benefits of CAST-DESIGNER
Very fast design speed
General design time in Cast-Designer：
Standard casting Ten minute to one hour
Complex 3D partition surface 1~2 hour
Easy to use
Streamline design method
Similar interface for all components
Full parametric design, pre-defined template
Natural design style
Natural design style, draft design approach
Support multi design plans

Major Benefits of CAST-DESIGNER

Fully CAD/CAE/MCAD integration
CAD Import/export (STEP, IGES, STL)
CAM export (STL)
MCAD version built in CAD environment
Design checking and evaluation
Online guide and wizard
Special tools for design checking and
evaluation

Easily customization
Design database generation and customization


Contact

THANK YOU!

For any further query please contact us
Email: info@auto-design-online.com
SKYPE: autodesignonline
Web: www.auto-design-online.com


Cast designer basic

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