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AnyCastingTMis professional software for casting analysis that minimizes the defects by predicting various defects that can occur during casting based on filling and solidification of the casting process.

AnyCastingTM can be applied to the analysis of all casting processes like high and low pressure die casting, sand casting, investment casting, centrifugal casting etc., and it provides accurate predictions with exceptionally rapid simulation speed based on multi-core systems.

AnyCastingTM consists of a window-based screen configuration which makes the system user friendly. Moreover, its openGL mode provides a lively screen when observing results.

  • Real Flow application using Hybrid Method
  • Simplified mesh work via Auto Mesh System
  • Entrapped air prediction during filling based upon accurate flow analysis
  • Prediction of solidification defects with various parameter combinations
  • Quantification of results using quantitative analysis
  • Easy to see results using various functions
  • Continuous update to reflect exact on-site condition
※ AnyCastingTM Detailed Information
  • High Pressure Die Casting
  • Low Pressure Die Casting
  • Sand Casting(Cast Iron/Steel)

It is the process mainly applied to nonmetallic alloys (Al, Mg, Zn). It supports casting for high gate products at high pressure.

Defects such like invasion of airs, cold shuts, inclusions can be removed by properly changing methods such as shape of runner, gate diameter, overflow position and size. Issues can happen like metal mold overheating caused by repetitive goods production, organization coarsening and cycle time delay. These may be minimized by keeping the metal mold temperature constant throughout the installing cooling line.

This is a process injecting air into a product through hot water supply stalk pushing up in opposite direction to force small pressure (air or inert gas)to the molten metal area within a closed container.

If the weight of the product increases and the shape is complicated, the method for increase in mold temperature should be adopted for directional solidification and the easy streaming of molten metal. If the temperature of mold is increased, delay to termination time causes a decrease in productivity and organization of product became rough and mechanical property can be lowered. To get sound product, proper gate and its positioning, pressurized condition and location of channel, setting the condition is very important.

Sand gravity casting is a method taken by the high melting point alloy casting like cast iron and cast steel.

Make mold from foundry sand and casting method like gate system and Raiser should be properly designed to control filling defects (airs, drops), solidification defects (shrinkage). Distribution of core gas. Prediction module of phase fraction considered alloy composition and mechanical characteristics. The image concerning solidification considering exothermic sleeve.

  • Gravity Tilt Pour Casting
  • Investment Casting
  • Centrifugal Casting

Gravity tilt casting is by as much as thirty percent improved compared to general sand casting in the mechanical properties such as tensile strength, elongation, machinability. And also the product quality can be increased with beautiful appearance.

Investment casting makes metal mold from ceramic material so that it mostly is applied to high melting point alloy like heat resistant alloy, grasps the location of unnecessary gate and thickness of runner based on filling result and can judge the effectiveness of Riser and runner through solidification time distribution. As a result, user can not only set the casting method for certain product and condition but also seek enhancement in entire yield rate.

This is a casting method that pours molten metal into fast centrifuging Mold and triggers cooling and solidification to gain organizational precision and single directional solidification organization. It supports an optimal casting method for horizontal and vertical centrifugal casting.

  • Automobile

    Simulation cases of automotive parts

  • Electronics

    Simulation cases of electronics such as cell phones, laptops, etc.

  • Heavy Industries

    Simulation cases of large castings used in shipbuilding industry.

  • Special Casting

    Simulation cases of continuous casting such as PFC, Strip Casting, etc.

REAR HEAD

It is a part of an automobile compressor and its compressor works by the engine of automobile. Its principle is based on intake, compression and circulation of refrigerant. Compress the refrigerant at low pressure to be at high temperature and pressure and send it to condenser.

Satisfaction for Performance of Air compressor Components(SPEC)

  • Protect from immature forming by local temperature drop
  • Internal and external Leak no defect
  • Remove air Air,Oxide and Shrinkage
Production Material ADC12
Liquid Line/Solidus Injection 580℃ / 515℃
Temperature 630℃
Weight 3.34 kg
Mold Material SKD61
The initial temperature 190℃
Plunger Diameter 80mm
Slow/Fast 0.28 ▶ 3.0 m/sec

Analysis of above product using AnyCasting predicted both the consequence of prediction from the air isolation result calculated by accurate flow based on real flow and temperature distribution during injection and oxide produced from injection.

Temperature result during injection

  • Liquid Line : 580℃
  • Solidus Injection : 515℃
  • Only around 10℃ drop in temperature within the inside is only predicted rather than miss run due to temperature drop during pouring for the current product.

Air isolation result

  • If air isolation is found at the region where filling is not complete due to molten metal flow characteristics, it is considered high potential for air isolation.

Solidification contraction defect result

  • The area is one of the most frequently occurring places of shrinkage defects and when the final solidification is ongoing.

OIL PUMP HOUSING

This is thick-walled region so there is high probability of shrinkage defect in this region. Pressure pin method was applied to work out this issue. It is the part connected to automobile engine and serves to pump the oil within engine through lubricating line. It consists of housing and its cover where this analysis was applied. Its pumping part serves to transfer oil and consists of the apparatus converting required pressure which is divided into pressure port and intake port.

Analysis result point

  • Predict air distribution region during molten metal flow
  • Predict molten metal temperature decreased area
  • Predicting oxide captured region
Production Material ADC12
Liquid Line/Solidus Injection 580℃ / 515℃
Temperature 630℃
Weight 3.34 kg
Mold Material SKD61
The initial temperature 190℃
Plunger Diameter 80mm
Slow/Fast 0.28 ▶ 3.0 m/sec

Analysis on above product by using AnyCasting is applied the following cases. The analysis applies to the miss run area decided by temperature analysis, defining air isolation defect location through the accurate flow analysis technique based in Real Flow, prediction on the modeling oxide final distributed area and the contraction defect area through prediction of solidification pattern.

Air isolation result

  • The air isolation is highly probable in the area where finally indicated filling has happened.

Temperature result during injection

  • Liquid Line : 580℃
  • Solidus Injection : 515℃
  • In the finally filled region indicated at stationary shaft, molten metal of drop in 20℃ degrees Celsius versus injected temperature 640℃ is distributed but it is higher than the solidus line so that unfilled defect during injection is not predicted.

Oxide distribution result

  • Oxide is not discharged to the right side of overflow and remains in the indicated region.

EGR HOUSING

If the amount passing through to EGR is increased, combustion temperature so that minimization of the exhaust gas of nitrogen oxide can be done. Sometimes EGR Cooler is equipped to lower the temperature. If the reducing portion to EGR is increased, combustion temperature can be lowered and content of nitrogen oxide will be decreased but minute soot particles will inversely increase.

Analysis result point

  • The air isolation region predicted by horizontal, vertical method
  • The core gas region predicted by horizontal, vertical method
  • The temperature distribution predicted by horizontal, vertical method
Production Material ADC12
Liquid Line/Solidus Injection 580℃ / 515℃
Temperature 630℃
Weight 3.34 kg
Mold Material SKD61
The initial temperature 190℃
Plunger Diameter 80mm
Slow/Fast 0.28▶3.0 m/sec
  • The analysis on above-mentioned product using AnyCasting is performed by comparing prediction on air isolation region, tracking final pathway for gas emitted from core and temperature distribution of filled molten metal based on comparative analysis on vertical and horizontal method.

Air isolation result

  • In the case of thr vertical method, final filling is performed in top part of product and air isolation within product is highly and probably predicted.

Core gas result

  • Gas emitted from core gas may exhaust through ventilation duct of some mold but the remaining gas moves along the stream of molten metal and is captured at an arbitrary location. Horizontal type cannot exhaust gas to Riser but filling pattern of horizontal type made most of gas captured at upper Riser.

Temperature distribution result

INTAKE MANIFOLD

Intake Manifold means many channels for intake, the number of the cylinder connected to carburetor or throttle body. It is a kind of pipe where air or mixed gas is mixed, consisting of cast iron, steel pipe and aluminum alloy. It has low inlet resistance and its number was evenly distributed to each cylinder.

Analysis result point

  • Filling pattern according to tilting casting method
  • Prediction on molten metal temperature distribution during injection
Material Material AC4C
Mold FCD370
Cores R.C.S
The initial Tempertaure The mel temperature 700˚C
Mold temperature 300˚C
Plunger Tilting time 17 sec
Tilting angle 90˚C

Analysis of above product using AnyCasting applied to predict both the air isolation result calculated by accurate flow based on real flow and temperature decrease region within the product during filling.

Air isolation result

  • It is predicted that filling was first performed in the top and bottom part of product during injection and then air isolation is highly probable in the center of product.

Temperature distribution result

  • It is predicted that a temperature drop by molten metal goes to near solidification temperature 560℃ at lower part of product filled initially, the dramatic drop in temperature at specific region affect organization homogeneity to result in mechanically bad characteristics.

TRANS MISSION CASE

Internal combustion engine like transmission(TM) for general automobile produces maximum torque at constant velocity but more powerful torque and lower rotation is required when it starts to run. When it runs more and more speedily, rotation velocity is more significant rather than torque. So when you start with gear to keep the rotation of engine steady, transmission causes decrease in the rotational velocity and increases torque. On speeding up, it is the role of transmission to increase the rotation number and its cover is called TM case.

Analysis result point

  • Final filling area prediction on filling
  • Prediction on air isolation region and gas isolation region
  • Prediction on temperature distribution during injection
Production Material MRI153M
Liquid Line/Solidus Injection 601˚C
Temperature 680˚C
Weight 6.9KG
Mold Material SKD61
The initial temperature 200˚C
Plunger Diameter 150mm
Slow/Fast 0.4 ▶ 3.5m/sec

The analysis on above-mentioned product using AnyCasting relates to the bubble isolation result calculated by the accurate flow and prediction on gas isolation region and temperature distribution during injection.

Filling analysis result

  • Final filling is expected to be performed on the indicated location in the case of circular product and air and gas isolation may take place.

Air and gas isolation result

  • It is predicted that most of the isolation may take place in the final filling region as shown in filling analysis result and gas also may be distributed over similar regions.

Temperature distribution result

  • Temperature drop of molten metal may take place during injection in the finally filled region but its location may be similar with gas isolation location. Temperature drop during injection serves gas and oxide to prohibit the migration and causes other defects besides miss run.

Cell Phone Case

Today most mobile phone manufacturers tend to concentrate all their efforts on production of thin layered products so that more ultra-thin cases are required. But thin layered plate has some problems such as charging, air, oxide and transformation due to flow decline of molten metal.

Analysis result point
Prediction on temperature distribution during injection
Prediction on distribution area of air and oxide
Prediction on thermal transformation

Charging aspects results

Molten metal injection had two different points according to the result of filling pattern. But case 2 of the injection pattern was unstable compared to case 1.
- Air isolation is highly probable.

Case 1
Case 2
Case 1

Temperature distribution result

  • 런Observing result of temperature distribution according to runner location, unsafe pouring pattern due to shape in front of gate and molten metal temperature decrease are expected in Case 2
Case 2

Air isolation result

  • The isolated air region can be predicted using expression the region where pressure of the isolated air is higher than pressure of molten metal as pressure distribution.

Temperature and oxide result

  • Oxide distribution is expressed high level at the region where molten metal temperature during filling decreases. Oxide moves along the molten metal flow but it does not move anymore and tend to be captured when it contact the temperature decreasing region where the fluidity of molten metal is weakening.

Thermal deformation result

Defect from thermal deformation in sheet metal product is one of the major defects. Degree of deformation and the place where stress is focused can be predicted.

Impeller

A body of rotation which consisted of plural wings mounted onto axis and the part where energy exchange with shaft power will take place is also called impeller. When it gives energy to fluid like Pump, blower and compressor, we call it impeller. When it receives energy like waterwheel, we call it runner. We classify as a centrifugal force type, Supercritical flow type and Axial flow type according to the direction to which fluid comes through impeller.

Analysis result point
Prediction on temperature distribution result on filling
Prediction on oxide distribution region

Temperature distribution result

Injection of molten metal begins from lower part to upper part in order but an extended injection time will make the temperature drop at the lower blade part of the product.

Oxide distribution result

It is predicted that most of the oxide flowed to the upper part of the product where Riser is located but captured oxide cannot move within the blade region where molten metal temperature falls and will remain with product.

Solidification pattern and shrinkage defect result

  • Final solidification takes place in the center of product and Riser circling the center maximized feeding by the exothermic sleeve effect. As a result, contraction within product was predicted in the center of product. It was under examination to use sleeve and exothermic agent to central Riser to reform it Analysis result point.

Impeller Blade

Analysis result point
Prediction on contraction result pattern according to the size of Riser
Prediction on contraction result pattern according to casting method

Shrinkage defect result according to the size of Riser

  • Size of Riser which is installed upon the upper of product is proportional to the location of shrinkage defect. But, when the size of Riser is big, the contraction defect location tends to go up to feeder but recovery rate falls. It is necessary to find means to increase the efficiency of Riser or exchange methods using exothermic powder.

Shrinkage defect result according to method change

  • It is considered that when result of horizontal method and vertical method is compared, casting by horizontal method for current product will probably serve to produce a good quality product.

Continuous Casting process optimization using Nitinol alloy

This is optimal method to prepare sound Billet using numerical analysis. This requires many parameters to adjust to find the condition for optimal process like heat transfer coefficient, withdrawal velocity, cooling condition of mold Analysis on the continuous casting process demands the accurate heat property according to materials of each part. Each result depends on the coefficient of each materials and machine status and the like. So it is very significant that calculation of basic values based on comparison between test results and their analysis.

Temperature distribution according to withdrawal velocity (injection temperature 1350℃)

Temperature distribution according to withdrawal velocity (injection temperature 1400℃)

Optimization for uranium thin plate process parameter using PFC process

Uranium Foil is the material for nuclear fuel in research reactors and raw material of radioisotopes for cancer diagnosis which is used in special areas. The existing hot rolling method required several repetitive rolling at 600℃ and rapid cooling and it has several problems like difficulties related to time and conditions, expense and labor and the like compared with Planar Flow Casting (PFC). This study tried to find out the optimal solution over PFC method using numerical analysis

Diagram for Single Roll PFC method and melt flow within Tundish

Integrity evaluation for Foil according to the rotation speed of Roll

In PFC process using rapid solidification method, above-mentioned case, if Roll velocity increases, molten metal emitted within Tundish is solidified to produce stable thickness of Foil. It is predicted when velocity increases as do graph show, standard deviation of Foil thickness is lowly distributed.

Foil Integrity evaluation according to the rotational velocity of Roll