Z-CastPro Manual 50

Chapter 5
5. Tutorial

overview This chapter explains the process for sand casting.

contents 1. Sand casting

2. Diecasting
3. Shotsleeve
4. Low pressure
5. Cycle casitng
6. Tilting casting
51

5-1 Sand casting

1) Make Project
Systematic management for all the conditions for the product information and the
analysis result
1) Click New icon
2) Select workspace folder: Select the folder which is saved the STL files
3)Create ‘*.ezp’ for new work files

2) Model File Import

Open STL files by modeling in 3D CAD
1) Click ‘Add Stl Model’ of [Pre process] in Command window
2) Open STL files.

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3) Make mold and input shape information of casting

You can make mold simply.
1) Click ’Make Mold’ icon of [Model Window]
2) Input “0” in Z+ direction and make mold.

3) Input shape information

① Select shape of ‘Type’ of [Model Window].
- Auto Type: if you open “Body12_cast.stl” files, the type will be Metal.
- For considering priority, change the order.
(Metal>Gate>riser>Sleeve>Mold)

Click right mouse

button and select Type
53

4) Generate Mesh
1) Generate mesh for analysis.
2) Click “Generate Mesh” of ‘Preprocess’ in [Command Window]
3) Check ‘Generate Mesh for Actual shape’ Mesh Generation
4) Use scroll bar and check total number of cell

5) Set material
1) Set each material and initial temp.

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6) Set ingate
1) Set ingate
2) Click ‘Set Ingate’ of ‘Pre process’ in [Command Window]
3) Select ‘Time’ of [Ingate Type].
4) Input 5sec, and select ‘Z+’ for Pouring Direction
5) Click “OK and drag ingate size.
(The high of ingate and riser must be same)
55

7) Set sensor
1) Insert thermocouple and marker.
2) Click ‘Set Sensor’ of ‘Pre process’ in [Command Window]
3) Select ‘Thermocouple’ of ‘View Mesh Sensor’ and move the section (which
you want) in Mesh View Window and insert Sensor.
4) In case of Marker, Inset marker after selecting Path line Marker in ‘View Mesh
Sensor’
5) After inserting, and then click ‘End Sensor’

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8) Set Solver Environment

Set Solver Environment (1) – General Settings

1) Click “Set Solver Environment “in [Pre Process] of Command

2) Select “Flow + Solidification Analysis “
3) Input “-9810” Gravity velocity for Z axis
4) After inputting general condition, click Next button.

Set Solver Environment (2) – Flow Parameters

1) Analysis terminate conditions are Flow rate and Time.
2) Select Calculation Performance.
3) Input wall Condition. It is slip and no slip so input 0~1. Here input 0.6
[Sand casting (0.4~0.6), gravity die casting, low casting (0.8), die casting (1)]
4) Relaxation factor (1.0~2.0) considers convergence and safety of calculation.
If the value is bigger, the speed is faster but safety decreases. Generally input
1.3
5) Select ‘FDM’ in [Advanced Option] and click Next
PLIC : Because the calculation of molten surface is more accuracy, so it improve
accuracy of flow analysis.
Tilting : Input Tilting condition in case of tilting casting.
57

Set Solver Environment (3) – Save Flow Data

1) No. Data of Save: In case of omission for 50 substructures for [Save Data],
automatically 50 steps are saved.
2) Check the saving for temperature, velocity, pressure, filling time result
3) When input the marker or sensor, check the Path line Marker and Save Sensor
Data.
Input saving interval.
4) You can save the flow analysis result for each filling rate or time, and here
input 2% filling rate for saving.

5) Click ‘Next’

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Set Solver Environment (4) – Solid Parameters

1) Exothermic material for the riser: if you use it, please check
2) Set adiabatic condition automatically: when you analysis axis 1/2, 1/4 for
symmetry product, this option designates the planes of symmetry automatically.
3) Check ‘Use Shrinkage Solver’ (the calculation method is supplemented
shrinkage amount by Water level dropout of molten metal)
4) This is cast so, input 6% at volumetric shrinkage (%)
5) Critical Solid fraction(%): If molten metal is solidificated over definitely part,
solidificated molten metal hinder the liquidity (liquidity prediction Index) here
input 60%. (The higher the value, liquidity is good.)
6) Temperature for shrinkage is the air temperature of shrinkage part during
analysis, here input 1300°C.
59

Set Solver Environment (5) – Save Solid Data

Set Solver Environment (6) – Heat transfer coefficient

Check the Heat transfer coefficient and click OK.

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9) Result

< Flow temp.> < Solid time.>

< Soild temp. > < Liquid State >

< Shrinkage > < Niyama >

61

5-2 Diecasting
1) Make Project
Systematic management for all the conditions for the product information and the
analysis result
1) Click New icon
2) Select workspace folder: Select the folder which is saved the STL files
3)Create ‘*.ezp’ for new work files

2) Model File Import

Open STL files by modeling in 3D CAD .
1) Click ‘Add Stl Model’ of [Pre process] in Command window
2) Open STL files.

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3) Make mold and input shape information of casting

You can make mold simply.
1) Click ’Make Mold’ icon of [Model Window]
2) Check 10% offset as default value, and click OK button

3) Input shape information

① Select the shape of Type in Model tap.
- Auto Type: if you open “Body12_cast.stl” files, the type will be Metal.
- For considering priority, change the order.
(Metal>Gate>riser>Sleeve>Mold)

Click right mouse

button and select Type
63

4) Generate Mesh
1) Generate mesh for analysis.
2) Click “Generate Mesh” of ‘Preprocess’ in [Command Window]
3) Check ‘Generate Mesh for Actual shape’ Mesh Generation
4) Use scroll bar and check total number of cell

5) Set material
1) Set each material and initial temp.

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6) Set ingate
1) Set ingate
2) Click ‘Set Ingate’ of ‘Pre process’ in [Command Window]
3) Select ‘Time’ of [Diecasting].
4) Input 15sec, and select ‘Z+’ for Diecasting
5) Click “OK and drag ingate size.
(The high of ingate and riser must be same)

< Ingate dailog >

65

7) Set sensor
1) Insert thermocouple and marker.
2) Click ‘Set Sensor’ of ‘Pre process’ in [Command Window]
3) Select ‘Thermocouple’ of ‘View Mesh Sensor’ and move the section (which
you want) in Mesh View Window and insert Sensor.
4) In case of Marker, Inset marker after selecting Path line Marker in ‘View Mesh
Sensor’
5) After inserting, and then click ‘End Sensor’

Insert Sensor. Insert Marker which you want

< Sensor setting window > < Marker setting window >

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8) Set Solver Environment

Set Solver Environment (1) – General Settings

1) Click “Set Solver Environment “in [Pre Process] of Command
2) Select “Flow + Solidification Analysis “
3) Input “-9810” Gravity velocity for Z axis
4) After inputting general condition, click Next button.

Set Solver Environment (2) – Flow Parameters

1) Analysis terminate conditions are Flow rate and Time.

2) Select Calculation Performance.
3) Input wall Condition. It is slip and no slip so input 0~1. Here input 0.6
[Sand casting (0.4~0.6), gravity die casting, low casting (0.8), die casting (1)]
4) Relaxation factor (1.0~2.0) considers convergence and safety of calculation.
If the value is bigger, the speed is faster but safety decreases. Generally input
1.3
5) Select ‘FDM’ in [Advanced Option] and click Next
PLIC : Because the calculation of molten surface is more accuracy, so it improve
accuracy of flow analysis.
Tilting : Input Tilting condition in case of tilting casting
67

Set Solver Environment (3) – Save Flow Data

1) No. Data of Save: In case of omission for 50 substructures for [Save Data],
automatically 50 steps are saved.
2) Check the saving for temperature, velocity, pressure, filling time result
3) When input the marker or sensor, check the Path line Marker and Save Sensor
Data.
Input saving interval.
4) You can save the flow analysis result for each filling rate or time, and here
input 2% filling rate for saving.

5) Click “Unuse” in Semi-Solid.

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Set Solver Environment (4) – Solid Parameters

1) Exothermic material for the riser: In case of Die casting, uncheck it.
2) Set adiabatic condition automatically: when you analysis axis 1/2, 1/4 for
symmetry product, this option designates the planes of symmetry automatically
3) Uncheck ‘Use Shrinkage solver’ because this is high pressure die casting.

Set Solver Environment (5) – Save Solid Data

69

Set Solver Environment (6) – Heat Transfer Coefficient

Check the default HTC and click “OK” button.

9) Result

< Flow temp. > < Marker >

< Unfilled > < Sold Temp. >

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5-3 Shot sleeve

1) Make Project
Systematic management for all the conditions for the product information and the
analysis result
1) Click New icon
2) Select workspace folder: Select the folder which is saved the STL files
3)Create ‘*.ezp’ for new work files

2) Model File Import

Open STL files by modeling in 3D CAD .
1) Click ‘Add Stl Model’ of [Pre process] in Command window
2) Open STL files.
71

3) Make mold and input shape information of casting

1) In case of there is no mold, make the mold using ‘Make Mold’
2) In case of Mold, the real size mold is good but if the mold size is big, the
mesh number increase and the calculation time is slow. So make the proper
size.
▶In case of shot sleeve, the coordicate of Plungger is X- -> X+

Using “Rotate for the

Axis” function, you can
change the axis .

3) Input shape information

① Select the shape of Type in Model tap.
- Auto Type: if you open “Body12_cast.stl” files, the type will be Metal.
- For considering priority, change the order.
(Metal>Gate>riser>Sleeve>Mold)

Click right mouse

button and select Type

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4) Generate Mesh
1) Generate mesh for analysis.
2) Click “Generate Mesh” of ‘Preprocess’ in [Command Window]
3) Check ‘Generate Mesh for Actual shape’ Mesh Generation
4) Input 0.01 at Mesh Cell Tolerance.
5) Use scroll bar and check total number of cell

5) Set material
1) Set each material and initial temp.

Material

Initial temp.
73

6) Set ingate
1) Set ingate
2) Click ‘Set Ingate’ of ‘Pre process’ in [Command Window].
3) Select ‘Shotsleeve ‘of [Ingate Type]
4) Input shotsleeve parameters.
5) Click “OK and move the section, and set the ingate.

ingate

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7) Set sensor
1) Insert thermocouple and marker.
2) Click ‘Set Sensor’ of ‘Pre process’ in [Command Window]
3) Select ‘Thermocouple’ of ‘View Mesh Sensor’ and move the section (which
you want) in Mesh View Window and insert Sensor.
4) In case of Marker, Inset marker after selecting Path line Marker in ‘View Mesh
Sensor’
5) After inserting, and then click ‘End Sensor’

8) Set Solver Environment

Set Solver Environment (1) – General Settings

1) Command Window Pre Process 에서 Set Solver Environment

2) Select “Flow + Solidification Analysis “
3) Input “-9810” Gravity velocity for Z axis
4) After inputting general condition, click Next button.
75

Set Solver Environment (2) – Flow Parameters

1) Analysis terminate conditions are Flow rate and Time.

2) Select Calculation Performance.
3) Input wall Condition. It is slip and no slip so input 0~1. Here input 0.6
[Sand casting (0.4~0.6), gravity die casting, low casting (0.8), die casting (1)]
4) Relaxation factor (1.0~2.0) considers convergence and safety of calculation.
If the value is bigger, the speed is faster but safety decreases. Generally input
1.3
5) Select ‘FDM’ in [Advanced Option] and click Next
PLIC : Because the calculation of molten surface is more accuracy, so it improve
accuracy of flow analysis.
Tilting : Input Tilting condition in case of tilting casting

Set Solver Environment (3) – Save Flow Data

1) No. Data of Save: In case of omission for 50 substructures for [Save Data],
automatically 50 steps are saved.
2) Check the saving for temperature, velocity, pressure, filling time result
3) When input the marker or sensor, check the Path line Marker and Save Sensor
Data.
Input saving interval.
4) You can save the flow analysis result for each filling rate or time, and here
input 2% filling rate for saving.

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5) Click “Unuse” in Semi-Solid.

Set Solver Environment (4) – Solid Parameters

1) Exothermic material for the riser: In case of Die casting, uncheck it.
2) Set adiabatic condition automatically: when you analysis axis 1/2, 1/4 for
symmetry product, this option designates the planes of symmetry automatically
3) Uncheck ‘Use Shrinkage solver’ because this is high pressure die casting.
77

Set Solver Environment (5) – Save Solid Data

Set Solver Environment (6) – Heat Transfer Coefficient

Check the default HTC and click “OK” button.

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9) Result

< Flow temp. >

< Flow temp. > < UnFiling >

< Solid temp. > < Liquid State >

79

5-4 Low pressure casting

1) Make Project
Systematic management for all the conditions for the product information and the
analysis result
1) Click New icon
2) Select workspace folder: Select the folder which is saved the STL files
3)Create ‘*.ezp’ for new work files

2) Model File Import

Open STL files by modeling in 3D CAD
1) Click ‘Add Stl Model’ of [Pre process] in Command window
2) Open STL files.

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3) Make mold and input shape information of casting

1) In case of there is no mold, make the mold using ‘Make Mold’
2) In case of Mold, the real size mold is good but if the mold size is big, the
mesh number increase and the calculation time is slow. So make the proper
size.

Using “Rotate for the

Axis” function, you can
change the axis .

3) Input shape information

① Select shape of ‘Type’ of [Model Window].
- Auto Type: if you open “Body12_cast.stl” files, the type will be Metal.
- For considering priority, change the order.
(Metal>Gate>riser>Sleeve>Mold)

Click right mouse

Set model as priority button and select type
81

4) Generate Mesh
1) Generate mesh for analysis.
2) Click “Generate Mesh” of ‘Preprocess’ in [Command Window]
3) Check ‘Generate Mesh for Actual shape’ Mesh Generation
4) Input 0.001 at Mesh Cell Tolerance.
5) Use scroll bar and check total number of cell

5) Set material
1) Set each material and initial temp.

Material

Initial temp.

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6) Set ingate
1) Set ingate.
2) Click ‘Set Ingate’ of ‘Pre process’ in [Command Window].
3) Select ‘Pressure’ of [Ingate Type].
4) Input low pressure parameters.
5) Click “OK and move the section and insert ingate. (Injection direction : Z-)

Ingate
83

7) Set sensor
1) Insert thermocouple and marker.
2) Click ‘Set Sensor’ of ‘Pre process’ in [Command Window]
3) Select ‘Thermocouple’ of ‘View Mesh Sensor’ and move the section (which
you want) in Mesh View Window and insert Sensor.
4) In case of Marker, Inset marker after selecting Path line Marker in ‘View Mesh
Sensor’
5) After inserting, and then click ‘End Sensor’

< Insert sensor> < Insert marker>

8) Set Solver Environment

Set Solver Environment (1) – General Settings
1) Click “Set Solver Environment “in [Pre Process] of Command
2) Select “Flow + Solidification Analysis “
3) Input “-9810” Gravity velocity for Z axis
4) After inputting general condition, click Next button.
.

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Set Solver Environment (2) – Flow Parameters

1) Analysis terminate conditions are Flow rate and Time.
2) Select Calculation Performance.
3) Input wall Condition. It is slip and no slip so input 0~1. Here input 0.6
[Sand casting (0.4~0.6), gravity die casting, low casting (0.8), die casting (1)]
4) Relaxation factor (1.0~2.0) considers convergence and safety of calculation.
If the value is bigger, the speed is faster but safety decreases. Generally input
1.3
5) Select ‘FDM’ in [Advanced Option] and click Next
PLIC : Because the calculation of molten surface is more accuracy, so it improve
accuracy of flow analysis.
Tilting : Input Tilting condition in case of tilting casting

Set Solver Environment (3) – Save Flow Data

1) No. Data of Save: In case of omission for 50 substructures for [Save Data],
automatically 50 steps are saved.
2) Check the saving for temperature, velocity, pressure, filling time result
3) When input the marker or sensor, check the Path line Marker and Save Sensor
Data.
Input saving interval.
4) You can save the flow analysis result for each filling rate or time, and here
input 2% filling rate for saving.
85

5) Click “Unuse” in Semi-Solid.

Set Solver Environment (4) – Solid Parameters

1) Exothermic material for the riser: Uncheck it because this is low pressures
casting.
2) Set adiabatic condition automatically: Set adiabatic condition automatically:
when you analysis axis 1/2, 1/4 for symmetry product, this option designates
the planes of symmetry automatically.
3) Uncheck ‘Use shrinkage solver’

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Set Solver Environment (5) – Save Solid Data

Set Solver Environment (6) – Heat transfer coefficient

Check the Heat transfer coefficient and click OK
87

9) Result

< Flow temp. &Marker >

< Solid temp. >

< Liquid State > < Graph >

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5-5 Cycle casting

1) Make Project
Click “Open Project ” and open the result of low pressure casting.

2) Set sensor
1) Click ‘Set Sensor’ of ‘Pre process’ in [Command Window]
2) Select ‘Thermocouple’ of ‘View Mesh Sensor’ and move the section (which
you want) in Mesh View Window and insert Sensor.
3) After inserting, and then click ‘End Sensor’.
**After finish cycle casting, you can insert the sensor and check it through Graph
Sensor

Insert sensor
89

3) Set Solver Environment

Set Solver Environment (1) – General Settings

1) Click “Set Solver Environment “in [Pre Process] of Command

2) Select “Cycle Analysis “
3) Input “-9810” Gravity velocity for Z axis
4) After inputting general condition, click Next button.

Set Solver Environment (2) –Cycle variable

 No. of Cycle : Cycle number for the mold temperature heat and the cycle
analysis number for stabilizing.

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 Mold Closed Time : The mold is closed and the time just before the open
again.
 Mold Opened Time : The mold is opened and the time just before the
close again.
 Heat Transfer Coefficient for mold opened : After open mold, and the
heat transfer coefficient at the cavity part
 Use Flow Temperature Data : When the cycle analysis start using flow
analysis result, , initialize it (input invoked cycle number)
 Press : Heat transfer coefficient for pressure section
Coefficient: Input pressure size (1: non pressure state 2:
Double size of non pressure state)
Start: Pressures start time
End: Pressures end time
 Spray : Spray state for open section
Coefficient: Input spray size
Start: spray start time
End : spray end time
 1st : 1st pressure(The pressure required to raise up ingate.)
 2nd : 2nd pressure (The pressure required to raise up the top of product
from ingate)
3rd
 3rd : pressure (pressurize pressure- riser effect)
 keep : keep the 3rd pressure state (casting pressure)
 exhaust : Pressure exhaust

Set Solver Environment (3) – Set Solver Environment

1) Exothermic material for the riser: Uncheck it because it is cycle analysis of low
pressure casting
2) Set adiabatic condition automatically: when you analysis axis 1/2, 1/4 for
symmetry product, this option designates the planes of symmetry automatically.
3) Uncheck ‘Use shrinkage solver’
91

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Set Solver Environment (4) – Save Cycle Data

Set Solver Environment (5) – Cooler

93

Set Solver Environment (6) – Heat transfer coefficient

Check the Heat transfer coefficient and click OK.

4) Result

< Graph & Solid temp. >

< Section view >

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< Solid temp. >

< Function Bar를 이용한 온도구간보기> < Solid temp. >

<1Cycle Solid temp. > <9 Cycle Solid temp.>

95

5-6 Tilting casting

1) Make Project
Systematic management for all the conditions for the product information and the
analysis result
1) Click New icon
2) Select workspace folder: Select the folder which is saved the STL files
3)Create ‘*.ezp’ for new work files

2) Model File Import

Open STL files by modeling in 3D CAD
1) Click ‘Add Stl Model’ of [Pre process] in Command window
2) Open STL files.

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3) Make mold and input shape information of casting

You can make mold simply. .
1) Click ’Make Mold’ icon of [Model Window]
2) You can make the mold of cast and basin separately.
Select model file at “Select Volume” and make the mold through Mold Margin.

3) Input shape information

① Select shape of ‘Type’ of [Model Window].
- Auto Type: if you open “Body12_cast.stl” files, the type will be Metal.
- For considering priority, change the order.
(Metal>Gate>riser>Sleeve>Mold)

Click right mouse

button and select Type
97

4) Generate Mesh
1) Generate mesh for analysis.
2) Click “Generate Mesh” of ‘Preprocess’ in [Command Window]
3) Check ‘Generate Mesh for Actual shape’ Mesh Generation
4) Use scroll bar and check total number of cell

5) Set material
1) Set each material and initial temp.

Material and initial

temp. setting

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6) Set sensor
The ingate setting for tilting casting is set at [Set Solver Environment].
1) Insert thermocouple and marker.
2) Click ‘Set Sensor’ of ‘Pre process’ in [Command Window]
3) Select ‘Thermocouple’ of ‘View Mesh Sensor’ and move the section (which
you want) in Mesh View Window and insert Sensor.
4) In case of Marker, Inset marker after selecting Path line Marker in ‘View Mesh
Sensor’
5) After inserting, and then click ‘End Sensor’

Insert sensor.. Insert Sensor which you want

< Sensor setting window > < Marker setting window >
99

7) Set Solver Environment

Set Solver Environment (1) – General Settings

1) Click “Set Solver Environment “in [Pre Process] of Command

2) Select “Flow + Solidification Analysis “
3) Input “-9810” Gravity velocity for Z axis
4) After inputting general condition, click Next button.
.

Set Solver Environment (2) – Flow Parameters

1) Analysis terminate conditions is Time [10]
2) Select Calculation Performance.
3) Input wall Condition. It is slip and no slip so input 0~1. Here input 0.6
[Sand casting (0.4~0.6), gravity die casting, low casting (0.8), die casting (1)]
4) Relaxation factor (1.0~2.0) considers convergence and safety of calculation.
If the value is bigger, the speed is faster but safety decreases. Generally input
1.3
5) Select ‘FDM’ in [Advanced Option] and click Next
PLIC : Because the calculation of molten surface is more accuracy, so it improve
accuracy of flow analysis.
Tilting : Input Tilting condition in case of titling casting (time:0,10 and angle:0,90)

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Set Solver Environment (3) – Save Flow Data

1) No. Data of Save: In case of omission for 50 substructures for [Save Data],
automatically 50 steps are saved.
2) Check the saving for temperature, velocity, pressure, filling time result
3) When input the marker or sensor, check the Path line Marker and Save Sensor
Data.
Input saving interval.
4) You can save the flow analysis result for each filling rate or time, and here
input 2% filling rate for saving.

5) Click “Unuse” in Semi-Solid

101

Set Solver Environment (4) – Solid Parameters

1) Exothermic material for the riser: Uncheck it becase of tilting casting
2) Set adiabatic condition automatically: when you analysis axis 1/2, 1/4 for
symmetry product, this option designates the planes of symmetry automatically
3) Check the “Use shrinkage Solver”

Set Solver Environment (5) – Save Solid Data

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Set Solver Environment (6) – Heat transfer coefficient

Check the Heat transfer coefficient and click OK

8) Reuslt

< Flow temp. >

103

< Flow temp. > < Unfilled >

< Solid temp. >

< Liquid State > < Shrinkage >

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