ANY SOFTWARE

Gas Defect Occurrence During & After Filling

Gas pressure is predicted by calculating the pressure of the melt & pressure in the air. Gas amount quantitatively predicts gas amount and isolation along with the gas amount in the melt. During filling, oxide can be tracked to predict the final isolated area, and leak defects can be predicted by considering shrinkage defects, machining areas and water/oil paths in the product.

Optimized Shot Sleeve

In the high pressure die casting process, the sleeve condition settings are the most basic procedure. Various types of defects occurring during filling can be predicted according to the low and high speed condition within the sleeve.

Realistic Vacuum Equipment Conditions

Based on the equipment settings, the user can easily check the pressure history by observing the pressure loss during vacuum use and the actual pressure graph applied to the product. By observing the actual pressure applied in the cavity, the user can optimize the vacuum equipment selection and apply it to real life.

Defects affecting Die Life

It is possible to increase die life and to derive casting conditions through prediction of soldering defects calculated by considering the surface treatment of the mold and product ejection time, along with the prediction of mold erosion defects caused by the speed, temperature of melt and shape of the mold during filling.

Predict Various Defects Caused by Deformation

Based on the temperature distribution result data, the deformation and cracking of the product can be predicted through mapping work using FEM mesh, and the effect of reducing shrinkage defects can be verified by using local squeeze pins when solidification occurs in a specific area of the product. In addition, it is possible to derive a safe eject pin position by predicting the safety factor of the mentioned eject pin.

Analysis of Shrinkage from Solidification Pattern & Gas

The area of residual melt isolated during solidification is tracked to predict areas with high possibility of macro shrinkage defects based on the probabilistic defect model. Micro shrinkage – which are difficult to predict by tracking residual melt, can be predicted by considering the gas concentration inside the melt during solidification leading to observing the growth mechanism of gas.

Improved Analysis Accuracy by Channel
Consideration

It is possible to maintain the temperature balance of the mold, control shrinkage defects, and minimize deformation by using cooling and constant temperature channels during solidification. For special channels such as spot channel cooling, heat transfer coefficients according to the length of the channel are set to be similar to the actual product. The user may take into account the cooling effect.

Reduce Time Consuming Work

Auto-Mesh creates meshes within 3-clicks for beginners. It detects the thickness of each area in the casting design, automatically adjusts the number of meshes, and generates meshes on the x, y, and z axis. In addition, it is possible to draft a report using the preset basic form through simple information input and observe the result like anyPOST in PowerPoint. Results Combination, which allows union and intersection combinations based on multiple results, enables various and clear result prediction.

Analysis of Shrinkage from Solidification Pattern & Gas

The area of residual melt isolated during solidification is tracked to predict areas with high possibility of macro shrinkage defects based on the probabilistic defect model. Micro shrinkage – which are difficult to predict by tracking residual melt, can be predicted by considering the gas concentration inside the melt during solidification leading to observing the growth mechanism of gas.

Thermal Properties Calculation

If there is no information to be used in the thermal property database within the program, the user can calculate the thermal property required for analysis by entering the chemical composition of the material. The thermal properties of a material are the most basic data in the analysis. In order to simulate accurately, the exact thermal data must be used.

Phase Distribution & Mechanical Property

For gray cast iron and ductile cast iron, phase (Pearlite, Ferrite, Graphite, Cementite) distribution can be predicted by considering the chemical composition value of each material and mechanical properties (Tensile Strength, Yield Strength, Hardness, Elongation) can be predicted.
This function is calculation range is below the solid transformation temperature in principle.

Core Gas Defect Before & After Filling

Gas Pressure is predicted by calculating the pressure of melt and isolated air area whereas Gas Amount predicts the movement, isolated distribution and amount of gas. It is possible to observe the movement of core gas generated from the contact in between the melt and the core along with the final isolated area. The results can then be expressed as a graph oh the amount of gas generated and discharged amount through the vent, etc.

Micro Shrinkage Defects using Gas Concentration

This is a method of identifying shrinkage defect areas that are difficult to predict by the observing the retained melt during solidification, which is generally used to identify defects by predicting gas in the melt. This method considers the growth of gas bubble in the molten metal during solidification, and is a method differentiated from other micro shrinkage defect prediction techniques.

Feeding Effect on Shrinkage Defects

In order to compensate for the shrinkage defect within the cavity, a riser is placed at the area of shrinkage. In order to maximize the effect of feeding, the size is determined in consideration of the casting yield. An exothermic sleeve or powder can be used for the effect of direction solidification to reduce shrinkage.

Inclusion Defects in Sand Casting

Sand drop and oxide defects are typical inclusion defects in the sand casting process. Defects caused by sand drop are dominant and through simulation, it is possible to predict the area where the melt impact during filling will affect the mold. In addition, it is possible to observe the change in the flow rate of the melt by installing a filter, so that the analysis considering the stability of the melt flow during filling is possible.

Reduce Time Consuming Work

Auto-Mesh creates meshes within 3-clicks for beginners. It detects the thickness of each area in the casting design, automatically adjusts the number of meshes, and generates meshes on the x, y, and z axis. In addition, it is possible to draft a report using the preset basic form through simple information input and observe the result like anyPOST in PowerPoint. Results Combination, which allows union and intersection combinations based on multiple results, enables various and clear result prediction.

Gas Defect Occurrence During & After Filling

Gas pressure is predicted by calculating the pressure of the melt & pressure in the air. Gas amount quantitatively predicts gas movement and isolation along with the gas amount in the melt. During filling, oxide can be tracked to predict the final isolated area, and leak defects can be predicted by considering shrinkage defects, machining areas and water/oil paths in the product.

Analysis of Shrinkage from Solidification Pattern & Gas

The area of residual melt isolated during solidification is tracked to predict areas with high possibility of macro shrinkage defects based on the probabilistic defect model. Micro shrinkage – which are difficult to predict by tracking residual melt, can be predicted by considering the gas concentration inside the melt during solidification leading to observing the growth mechanism of gas.

Thermal Properties Calculation

If there is no information to be used in the thermal property database within the program, the user can calculate the thermal property required for analysis by entering the chemical composition of the material. The thermal properties of a material are the most basic data in the analysis. In order to simulate accurately, the exact thermal data must be used.

Realistic Vacuum Equipment Conditions

Based on the equipment settings, the user can easily check the pressure history by observing the pressure loss during vacuum use and the actual pressure graph applied to the product. By observing the actual pressure applied in the cavity, the user can optimize the vacuum equipment selection and apply it to real life.

Oxide Prediction during Filling

In general, Al alloy is used in the low pressure die casting process, and due to the characteristics of Al alloy, it is vulnerable to oxidation. Oxide is formed due to air contact with the free surface of melt during filling, and there is a high probability of defects occurring in areas where the formed oxide is concentrated.

Micro Shrinkage Defects using Gas Concentration

This is a method of identifying shrinkage defect areas that are difficult to predict by the retained melt tracing method during solidification, which is a general shrinkage defect method, which is predicted by gas in the melt.
Microporosity calculations can consider external pressure. Using these points, microporosity is used when checking shrinkage defects in Counter Pressure Casting (CPC).

Improved Analysis Accuracy by Channel
Consideration

It is possible to maintain the temperature balance of the mold, control shrinkage defects, and minimize deformation by using cooling and constant temperature channels during solidification. For special channels such as spot channel cooling, heat transfer coefficients according to the length of the channel are set to be similar to the actual product. The user may take into account the cooling effect.

Reduce Time Consuming Work

Auto-Mesh creates meshes within 3-clicks for beginners. It detects the thickness of each area in the casting design, automatically adjusts the number of meshes, and generates meshes on the x, y, and z axis. In addition, it is possible to draft a report using the preset basic form through simple information input and observe the result like anyPOST in PowerPoint. Results Combination, which allows union and intersection combinations based on multiple results, enables various and clear result prediction.

Analysis of Shrinkage from Solidification Pattern & Gas

The area of residual melt isolated during solidification is tracked to predict areas with high possibility of macro shrinkage defects based on the probabilistic defect model. Micro shrinkage – which are difficult to predict by tracking residual melt, can be predicted by considering the gas concentration inside the melt during solidification leading to observing the growth mechanism of gas.

Thermal Properties Calculation

If there is no information to be used in the thermal property database within the program, the user can calculate the thermal property required for analysis by entering the chemical composition of the material. The thermal properties of a material are the most basic data in the analysis. In order to simulate accurately, the exact thermal data must be used.

Core Gas Defect Before & After Filling

Gas Pressure is predicted by calculating the pressure of melt and isolated air area whereas Gas Amount predicts the movement, isolated distribution and amount of gas. It is possible to observe the movement of core gas generated from the contact in between the melt and the core along with the final isolated area. The results can then be expressed as a graph oh the amount of gas generated and discharged amount through the vent, etc.

Gravity Tilting Pour Casting

In the gravity tilt casting, set the tilt axis and direction along with the center point when tilting and enter the angle according to the tilt time. The amount of melt in the hopper is automatically calculated and set within the program and the user can change it as well. Analysis from the melt pouring process in the hopper is also possible by modeling a separate gate on the upper surface of the hopper.

Determine Micro Shrinkage Defect with Gas Concentration

This is a method of identifying shrinkage defect areas that are difficult to predict by the observing the retained melt during solidification, which is generally used to identify defects by predicting gas in the melt. This method considers the growth of gas bubble in the molten metal during solidification, and is a method differentiated from other micro shrinkage defect prediction techniques.

Oxide Prediction during Filling

Most of the inclusions in the gravity tilting pour casting and the centrifugal casting are oxides. In the case of gravity tilting pour casting, it is necessary to check whether the generated oxides move to the riser area. In case of centrifugal casting, it is important to know where the generated oxides are finally located due to rotation.

Centrifugal Casting

Centrifugal casting is divided into horizontal and vertical types, and in detail, it can be divided into injection at the rotation center axis and injection at out of the rotation center axis. Analysis setting for all conditions of centrifugal casting is possible, input rotation speed (rpm) for rotation, and information on rotation axis, direction, and rotation center point are essential.

Reduce Time Consuming Work

Auto-Mesh creates meshes within 3-clicks for beginners. It detects the thickness of each area in the casting design, automatically adjusts the number of meshes, and generates meshes on the x, y, and z axis. In addition, it is possible to draft a report using the preset basic form through simple information input and observe the result like anyPOST in PowerPoint. Results Combination, which allows union and intersection combinations based on multiple results, enables various and clear result prediction.

Gas Defect Occurrence During & After Filling

Gas Pressure is predicted by calculating the pressure of melt and isolated air area whereas Gas Amount predicts the movement, isolated distribution and amount of gas. It is possible to measure the gas amount by entity and measure specific areas by using additional modeling.

Consideration of Radiation

In the case of investment casting with a higher shell mold temperature compared to other casting processes, the radiation effect due to surrounding temperature must be considered. In other words, since accurate consideration of the air temperature around the shell mold must be made, the radiation effect is considered by modeling of air layer and adjusting heat transfer coefficient.

Analysis of Shrinkage from Solidification Pattern & Gas

The area of residual melt isolated during solidification is tracked to predict areas with high possibility of macro shrinkage defects based on the probabilistic defect model. Micro shrinkage – which are difficult to predict by tracking residual melt, can be predicted by considering the gas concentration inside the melt during solidification leading to observing the growth mechanism of gas.

Micro Shrinkage Defect using Gas Concentration

This is a method of identifying shrinkage defect areas that are difficult to predict by the observing the retained melt during solidification, which is generally used to identify defects by predicting gas in the melt. This method considers the growth of gas bubble in the molten metal during solidification, and is a method differentiated from other micro shrinkage defect prediction techniques.

Oxide Prediction during Filling

Most of the common inclusion defects are oxides generated during filling and the generated oxides are distributed in the gate area that functions as a riser. However, in screw-shaped products such as propellers, oxides are concentrated in the blade area causing problems, so oxide analysis is also one of the important prediction results.

Increasing Productivity

When multiple products are produced in a single casting design, differences in soundness between each product may occur due to product placement, runner shape, and ingate shape and placement. Through functions such as changing the modeling location before analysis and experience over a long period of time, AnyCasting derives and presents the optimal plan for productivity improvement.

Reduce Time Consuming Work

Auto-Mesh creates meshes within 3-clicks for beginners. It detects the thickness of each area in the casting design, automatically adjusts the number of meshes, and generates meshes on the x, y, and z axis. In addition, it is possible to draft a report using the preset basic form through simple information input and observe the result like anyPOST in PowerPoint. Results Combination, which allows union and intersection combinations based on multiple results, enables various and clear result prediction.

Thermal Properties Calculation

If there is no information to be used in the thermal property database within the program, the user can calculate the thermal property required for analysis by entering the chemical composition of the material. The thermal properties of a material are the most basic data in the analysis. In order to simulate accurately, the exact thermal data must be used.

Shrinkage Defect due to Solidification Pattern

The area of melt that is isolated upon solidification is tracked to determine the shrinkage defect area using a probabilistic defect parameter technique. In the case of ingot casting, it is possible to predict micro-shrinkage in consideration of temperature gradient and to predict the cracking area inside of product using hot tearing intensity.

Thermal Properties Calculation

If there is no information to be used in the thermal property database within the program, the user can calculate the thermal property required for analysis by entering the chemical composition of the material. The thermal properties of a material are the most basic data in the analysis. In order to simulate accurately, the exact thermal data must be used.

Segregation Distribution Prediction

Among the defects occurring in ingot casting, segregation defects are one of the most important predictions to be made. The natural convection that occurs inside the product during solidification must also be considered. Based on the user input value, the difference in concentration are calculated to show the results which predict A segregation, V segregation, inverse segregation and negative segregation.

Prediction of Defects by Exothermic effect

In order to maximize the feeding effect of the riser, whether it is possible to consider the effect of the exothermic powder applied to the top of riser after filling is very important in the ingot casting analysis. It is possible to control defects generated in the product depending on the use of the exothermic powder and the performance of the exothermic powder.

Effect of Additional Pouring

Due to the nature of the ingot casting process, it is not possible to completely fill the mold with a single pour, so there must be additional pouring. It is crucial to consider the internal temperature and segregation that changes due to additional pouring and often intended to induce directional solidification.

Gas, Oxide & Slag

It is possible to check the behavior of gas and oxide & slag generated during filling and the final isolation location. These defects are harmful to the soundness of the ingot product and must be considered when checking the results of the filling analysis, through the quantitative analysis function, the amount of isolated gas in a specific area can be identified and the amount of isolation for each plan can be checked.

Increasing Productivity

In the ingot casting process, gating design and mold design come from experience of each manufacturer and are the factors that have a significant influence on the soundness of a product. Based on years of analysis experience using AnyCasting, optimizing the soundness of ingot products is presented and analytically verified.

Reduce Time Consuming Work

Due to the size of the product, the ingot casting process takes a long time to filling and solidification. Time loss occurs in the simulation. AnyCasting ingot casting analysis method provides a fast ingot solver function to minimize time loss, dramatically reducing the analysis time during filling.
This is the effect of reducing the analysis time by more than 2 times as much as the general analysis time.