Esi Quick Cast

Getting started with QuikCAST™ (HPDC / Shot)

Engineering Simulation for Industry

Getting Started with QuikCAST™

List of CAD Files

casting.stl

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Getting started with QuikCAST™

Import CAD Files

1

Select New option from the File Menu

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Getting started with QuikCAST™ Import CAD Files (Core)

2 3

4

Input Study Name Browse to define the Study Location

Click OK

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Getting started with QuikCAST™ Import CAD Files (Core)

5

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Browse and select the casting_HPDC.STL file

Click Open to load the CAD file in the model Window

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Getting started with QuikCAST™

Import CAD Files (Casting)

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Click OK

Define CAD File Unit System

( casting_HPDC.STL units is MM)

8

Activate Welding Point Operation

9

Input Tolerance value (mm)

10

Activate Automatic Fixing

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Getting started with QuikCAST™

Import CAD Files (Casting)

QuikCAST gives a description of the encountered problem when analysing the CAD files

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Click YES to continue

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Getting started with QuikCAST™

Import the CAD (Core)

HPDC Al geometry has been successfully imported

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Getting started with QuikCAST™

Automatic CAD Inlet Creation

Select Mesh Basic Shapes Option from the Model Menu

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Getting started with QuikCAST™

Automatic CAD Inlet Creation

1

Select By extrusion option

2 Input Extrusion Distance (Piston Chamber lenght)

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Getting started with QuikCAST™

Automatic CAD Inlet Creation

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3

Switch to Wire&Shaded display mode to display the facets

Entity selection must be set to Facet

5

Extruded geometry is automaticallydisplayed for

Select Facets located on the top of the tube ( SHIFT + left button)

each new selected facet

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Getting started with QuikCAST™

Automatic CAD Inlet Creation

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Click Close The inlet volume has been succefully created

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Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

In order to detect/assign volume materials select Domain Manager Option from the Model Menu

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Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

1 Activate the Create Contact surface option

2

Click Start to Start the Automatic Volume detection

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

New Surface Domains have been automatically created because the Create Contact surface option has been activated

4 Volume domains have been detected that need to be renamed and assigned with material properties.

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

2 Click View Volume to display the Volume_001

1 Select Volume_001 (left click)

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

3 Click Rename

4 Input Volume Domain Name

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

6

Select Alloy Volume type

7 Activate Standard DB

5 Click Material

8 Select AlSi9Cu3 Material from the material list

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

4 5 6 7 8 Repeat the steps to assign names and materials to the other volumes

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

9 10 Change Volume Priority order with the arrows ( Priority order should be defined according to the Filling order)

Click P to Activate Priority order

Getting started with QuikCAST™

Automatic Volume detection/Material Assignment

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12 Click Remove to delete the surface domains created during the import and during the automatic fixing sequence

Switch to Surface Domain panel

Getting started with QuikCAST™

3D Grid/FD Mesh Generation

Select 3D Grid/Mesh Generation option from the Model menu to generate the Grid

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Getting started with QuikCAST™

3D Grid/FD Mesh Generation

1

Activate Simplify Method

2

Select all the volumes

3

Input Mininum Size to fix global grid cell size (unit is meter)

4

Click Apply to generate the Grid

5

Click Run to generate the 3D Mesh

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Getting started with QuikCAST™

Define Gravity Direction

Select Gravity Option from the Process Menu

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Getting started with QuikCAST™

Define Gravity Direction

2 Click OK

1

Select PositiveZ direction and check Gravity Direction ( displayed in green) in the model window

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Getting started with QuikCAST™ Start the Model Set-up

Select Input Data Check from the Process Menu and a window with all available boundary conditions will appear on the left This window is used to manage all Boundary Conditions (BC) that will be applied to the model

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Getting started with QuikCAST™ Set-up the Metal Flow

1

Select Initial Fluid BC (left click) to set up the initial fluid rate for the filling

2

Click on Add... (right click) to open the panel definition

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Getting started with QuikCAST™

Set-up the Sand Flow

3 Input 40% and select Initial

5

Click OK

4 Select « Piston» and « Chamber » Volumes in the Volume list (left click)

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Getting started with QuikCAST™ Set-up the Metal Flow

1

2

Select Piston BC (left click) to set up the Sand Core Blowing pressure

Click on Add... (right click) to open the panel definition

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Getting started with QuikCAST™ Set-up the Metal Flow

3

Select Mold Material for the piston Material

4

Select Velocity Calculator Option to automatically calculate the transition from phase 1 to phase 2.i

5

Input Direction, Max Displacement and Velocity for phase 1 and 2

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Select « Inlet/Pressure1 » surface domain

Click OK

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Getting started with QuikCAST™

Set-up the Wall Flow laws

1

2

Select Temperature BC ( left click) to set up the metal injection temperature

Click on Add... (right click) to open the panel definition

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Getting started with QuikCAST™ Set-up the Metal Flow

3

Select Initial Option

4 5

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Input Alloy Material Temperature

Select Filling Option

Select « Chamber » and « piston » volume domains

Click OK

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Getting started with QuikCAST™

Set-up the Virtual Mold

1

Select Implicit Mold BC ( left click) to set up the Virtual Mold Material

2

Click on Add... (right click) to open the panel definition

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Getting started with QuikCAST™ Set-up the Metal Flow

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4

Select Die Material from the Standard DB list

5 6

Input Average Mold Thickness

Select the Surface domains having an interface with the die

Click OK

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Getting started with QuikCAST™

Set-up the Wall Heat Transfert

1

Select Die Coating BC ( left click) to set up the Virtual Mold Material

2

Click on Add... (right click) to open the panel definition

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Getting started with QuikCAST™ Set-up the Metal Flow

3

Input Average Coating Thickness

4

5

6

Select Coating Material from the Standard DB list

Select the Surface domains where the coating is applied

Click OK

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Getting started with QuikCAST™

Set-up the Output Solver Parameters

Select Output Parameter Option from the Calculation Menu

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Getting started with QuikCAST™

Set-Up the Output Solver Parameters

3

Activate the Filling Panel

4 Select by Percent (%) and input a value in the Graphics field. ( This will determine the number of states generated during the calculation

6

Click Close

5

Select the Variable Contours needed for post-processing

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Getting started with QuikCAST™

Run the Calculation

Select Calculation Start Option from the Calculation Menu

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Getting started with QuikCAST™

Run the Calculation

1

Activate Standard Calculation Option from the Filling/Solidification Panel

2

Enter Filling and Solidification Stop Criterias ( Time and/or Percentage of Filling/Solidification)

3

Activate High Pressure option

4

Click RUN to start the calculation This will open automatically the Monitor Calculation Window

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Getting started with QuikCAST™

Run the Calculation

> Calculation is running now

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Getting started with QuikCAST™

Post-Processing (Visual-CAST)

Select Open option from the File Menu

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Getting started with QuikCAST™

Post-Processing (Visual-CAST)

1

Select *.MCO file in the study directory

2 Click Open

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Getting started with QuikCAST™

Post-Processing Metal Flow (Visual-CAST)

1 Select Volumes to load

2

Click OK

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Getting started with QuikCAST™

Post-Processing Metal Flow (Visual-CAST)

3

Select Snapshot Option from the Results menu

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Getting started with QuikCAST™

Post-Processing Metal Flow (Visual-CAST)

4

Select THERMAL in Categories and Temperature in Results to display the temperature results during filling

5 If your calculation is still running, click Update to update the last calculated results

6

Select Arrows to display the differents states

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Getting started with QuikCAST™

Post-Processing Sand Flow Particules (Visual-CAST)

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Getting started with QuikCAST™

Post-Processing Examples (Visual-CAST)

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Getting started with QuikCAST™

Post-Processing Examples (Visual-CAST)

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Getting started with QuikCAST™ (HPDC Shot)

Engineering Simulation for Industry