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1. v Regular transition near boundary Chordal error Maximum chordal error in model relative 0 0 absolute 0 00e 000 Minimum element size 0 00e 000 Sphere mesher Algorithm Radius Expansion Max iterations 500 Others Smoothing Normal z Mesh until end V No mesh frozen layers Avoid elements with all its nodes in boundary Allow quadrilateral dominant meshes Mesh always by default NJ ql Figure F 5 Meshing preferences Click Accept and then Close the window GET STARTED TUTORIAL GRAVITY CASTING It is recommendable to first generate a triangular surface mesh in order to generate a good tetrahedral 3D mesh because this way we can check the mesh quality faster The steps to generate a good tetrahedral mesh will be e Generating a surface mesh e Check the quality of the mesh generated and make corrections if necessary e Return to geometry view and generate a geometrical volume out of the casting surfaces e Generate a tetrahedral mesh of the casting overwriting the previous mesh e Check again for mesh quality e Return to geometry and generate the mould volume and then generate the final casting and mould mesh overwriting the previous mesh this is the only mesh needed the previous ones were generated for verification Save the project before meshing Go to File Save as Go to the Mesh menu as shown in Figure
2. GRAVITY CASTING Step 4 FOUNDRY PROCESS DEFINTION Until now we were dealing with geometrical parameters definitions etc From now on we will deal with real foundry parameters characteristics processes etc It is very important to set the parameters properly The closer the parameters to reality the more accurate results So read on and let s do casting simulation The first step we take once we have the casting and mould geometry defined and meshed is let Vulcan know what type of process we are going to calculate Click on define the main process characteristic the 7 icon A window with 3 labels will appear In the Process type label select Gravity as shown in Figure F 15 GET STARTED TUTORIAL GRAVITY CASTING Process type General Symmetries Select process type y T Lost Foam M Low pressure Figure F 150 The Process type window Once this step is taken Vulcan adjusts all the internal parameters and the remaining icons to this particular type of process GET STARTED TUTORIAL GRAVITY CASTING In the General label we have a set options to define units gravity direction with respect to the coordinate system compass environment temperature etc Set the gravity direction to Z and the Environment temperature to 25 Degrees Celsius as shown in Figure F 16 fT Define the problem Process type General Symmetries Gravity constant 9 81 m s2 Environment temp
3. 1 Make sure that the activated layer 5 Highlight Select and select the is the profile layer By profile To conclude the operation dobleclick press the ESC key or click Finish in 2 In the Copy window select the line the Copy window The result is rotation Rotation Lines shown in Figure 15 3 Enter an angle of 36 degrees Make sure that the center is point 0 0 0 and that you are working in two dimensions 4 Inthe option Multiple Copies enter 9 This way 9 copies will be made thus obtaining the 10 teeth that form the profile of the model 9 copies and the original Figure 15 The part resulting from this process 2 12 Creating a surface 1 Create a NURBS surface To do this select the option Geometry Create gt NURBS Surface By Contour This option can also be found in the VULCAN Toolbox 2 Select the lines that define the profiel of the part and press ESC to create the surface 3 Press ESC again to exit the function The result is shown in Figure 16 Ce Figure 16 Creating a surface starting from the contour Gg NOTE To create a surface there must be a set of lines that define a closed contour B 14 VULCAN TUTORIALS 3 CREATING A HOLE IN THE PART In the previous sections we drew the profile of the part and created the surface In this section we will make a hole an octagon with a radius of 10 units in the surface of the part First we will draw the octagon 3 1 Creating two sides of the
4. 6 Define operations ra Save the project 8 Calculate 8 1 Process info 8 2 Kill the process These icons are placed in a logical order 1to6 Pre process 7 Save the project before calculate 8 Calculation We can completely define and calculate the casting component under study using this bar and in case necessary interrupt the calculation by clicking icon 8 2 Le s begin by opening Vulcan and then with the step by step guided tutorial GET STARTED TUTORIAL LPDC On the computer Desktop double click on the Vulcan icon the main screen will show up P Vulcan d a CETERE ETENE i EE E re ee E PA E ES Q es i s NIRS ae OTM CEC G7 SQ RO RKK SRA AD R y 110 motanals reot This i the PROFESSIONAL Version rm Commend A Figure H 2 Vulcan main screen Once Vulcan is opened go to the main menu and click on Data Problemtype Vulcan GET STARTED TUTORIAL LPDC The following window will appear Figure H 3 If the window doesn t appear you can go directly to Step 1 Select new problemtype You are going to load problemtype Vulcan What do you wantto do f Update to new problemtype All data information materials conditions data will be lost C Transform to new problemtype Data will be converted to new problemtype if possible Some data may be lost Cancel Figure H 3 Vulcan problemtype window Click OK and th
5. Ay nS A ES Figure 30 Importing the T junction file Figure 31 Here you can see that the to the main file Some points are importation creates a new layer if the duplicated and must be collapsed names are different C22 VULCAN TUTORIALS 3 Pass the imported geometry to ok layer 4 Choose the option Geometry gt Edit gt Collapse gt Lines Select the overlapping lines and press ESC and delete the sheared surface 5 2 Creating the final volume STEP 1 1 Choose Geometry gt Create gt Volume and select all the surfaces defining the volume Press ESC to conclude the selection process 2 Choose Render gt Smooth lighting to visualize a more realistic version of the model Figure 32 A rendering of the finished piece of equipment _VULCANTUTORIALS SS y OOB 6 GENERATING THE MESH Now that the model is finished it is ready to be meshed The mesh will be generated using Chordal Error in order to achieve greater accuracy in the discretization of the geometry The chordal error is the distance between the elements generated by the meshing process and the real profile of the model By selecting a sufficiently small chordal error the elements will be smaller in the zones with greater curvature 6 1 Generating the mesh using Chordal Error STEP 15 Choose the option Mesh gt Unstructured gt Sizes by Chordal error The minimum element size is automatically chosen VULCAN asks for the maximum element size Ent
6. Figure 16 Press ESC when the selection is finished Figure 17 Result of the rotation Ci UL AN TUTORIALS 3 4 Rotating the main pipe STEP 6 Eo 1 From the Copy window select Surfaces and Rotation Enter an angle of 60 degrees Since the rotation may be done in 2D choose the option Two Dimensions The center of the rotation is the intersection of the axes namely point 200 0 Be sure the Do Extrude menu is in the No mode 2 Click Select and select all the surfaces except those defining the elbow of the pipe Press ESC when the selection is finished AI Bl iiniie LL a J Figure 18 Geometry of the two pipes and the auxiliary lines VULCAN TUTORIALS C 15 3 5 Creating the end of the pipe 1 Figure 19 The circled points define step From the Copy window select Surfaces and Rotation Enter an angle of 180 degrees Since the rotation may be done in 2D choose the option Two Dimensions The center of rotation is the upper right point of the pipe eloow Make sure the Do Extrude menu is in the No mode Click Select and select the surfaces that join the two pipe sections In the Move window select Surfaces and Translation The points defining the translation vector are circled in Figure 19 Click Select and select the surfaces to be moved Press ESC Conon PP PY Figure 20 The final position of the translated elbow the translation vector 5 Choose Geometry gt Create gt NURBS Surface g
7. Now go to Mesh generate mesh Project UNNAMED Files View Geometry Utilities Data Workshop Calculate Help OS S SSWB S Lucus B B Fi QAIDQVeET Cartesian RECS MOS S 68 2 Boundary layer Mesh criteria gii K Reset mesh data OWM Ole FS 1R Draw aa lt Generate mesh w Ze W 7 Wig DAAE CA F S NAA i ANET p mr F J al P 7A 2 Drawing higherentities Press Escape to leave Leaving drawing Command Figure D 4 Mesh generation GET STARTED TUTORIAL GEOMETRY CORRECTION And enter an element size of 3 Figure D 5 Mesh size This is the result we get Mesh Generated Press OK to see it e l Num of Triangle elements 29078 Num of nodes 14527 Cancel Figure D 6 Generated mesh GET STARTED TUTORIAL GEOMETRY CORRECTION Now after clicking View mesh the meshed part will appear Figure D 7 Figure D 7 Triangular Finite Element mesh of the imported part The mesh of Figure D 7 is generated without errors but there are some areas in which the distortion of the elements could generate problems when it comes to calculation volume meshing etc It is important to correct as much as possible all the distorted elements GET STARTED TUTORIAL GEOMETRY CORRECTION Now we will examine the quality of this surface mesh by having a look at them and finding zones of d
8. Starting from this line we will create a square surface which will be meshed to obtain a surface mesh Finally we will use this surface to create a cubic volume from which a volume mesh can then be generated 1 CREATION AND MESHING OF A LINE We will begin the example creating a line by defining its origin and end points points 1 and 2 in the following figure whose coordinates are 0 0 0 and 10 0 0 respectively It is important to note that in creating and working with geometric entities Vulcan follows the following hierarchical order point line surface and volume s To begin working with the program open Vulcan and a new Vulcan project is created automatically From this new database we will first generate points 1 and 2 A 4 VULCAN TUTORIALS v O Next we will create points 1 and 2 To do this we will use an Auxiliary Window that will allow us to simply describe the points by entering coordinates Then from the Top Menu select Geometry Create Point and then select the sequence Utilities gt Tools Coordinates Window In the coordinate window opened previously the following indicated steps should be used U Coordinates window SS C System Cartesian 7 2 Create point 1 by ai Global z clicking on the button 1 Introduce eo 00000 Apply or by pressing the coordinates M Enter on the of point 1 0 00000 keyboard Create new point Ask iange Use tab Shift tab afid Retur
9. Tare aoey Name Cl VO F U Tr v S A Figure G 6 Layers control window Perform the following operations e Click on New button and create a new layer G A ET STARTED TUTORIAL HPDC Figure G 7 Layer selection and layer to use e Select the layer Layer0O enter the name cast in the textbox and click on Rename button e Select the layer Layer1 enter the name mould in the textbox and click on Rename button Tg NOTE The selected layer is highlighted in black After selecting a layer by simply clicking on it we can delete it rename it change its color turn it on and off send elements to it etc The layer to use instead is the layer with the checkmark in the layer to use we can create geometry delete it etc in the drawing Summary selected is to make changes using layers window and layer to use is the layer used to create delete or modify geometry We can change the layer to use by selecting a layer and click on Layer to use icon ___GETSTARTEDTUTORIAL HPDG Z o o y GH e Be sure that Layer to use is cast it says so beside the button and there is a checkmark v in the layer name e Select the layer mould and click on Send To button and then Surfaces e Goto the geometry and select the six surfaces that form the exterior of the mould e Turn off the layer mould e Select the layer cast click on Send To surfaces again and send all the casting surfaces to the l
10. Vulcan only allows the generati With this example the user has been introduced to the basic tools for the creation of geometric entities and mesh generation VULCAN TUTORIALS CASE STUDY 1 B IMPLEMENTING A MECHANICAL PART The objective of this case study is implementing a mechanical part in order to study it through meshing analysis The development of the model consists of the following steps e Creating a profile of the part e Generating a volume defined by the profile e Generating the mesh for the part At the end of this case study the user should be able to handle the 2D tools available in VULCAN as well as the options for generating meshes and visualizing the prototype B 2 VULCAN TUTORIALS This page is intentionally left blank VULCAN TUTORIALS B 3 1 WORKING BY LAYERS 1 1 Defining the layers A geometric representation is composed of four types of entities namely points lines surfaces and volumes A layer is a grouping of entities Defining layers in computer aided design permits us to work collectively with all the entities in one layer The creation of a profile of the mechanical part in our case study will be carrried out with the help of auxiliary lines Two layers will be defined in order to prevent these lines from appearing in the final drawing The lines that define the profile will be assigned to one of the layers called the profile layer while the auxiliary lines will be assigned to th
11. and go to the Step 6 Click again on the icon In case of having multiple layers you can assign and unassign layers to foundry components by using the gt icons for example in case of having the mould divided in upper part and lower part on different layers or in case of having to make changes Now click on the Add new foundry component icon The following window will appear Add a new foundry component Ea Name Wouldz Select a foundry component type 5 Fart Mould Filling system Chill Filter Feeding system Core Cooling system Sleeve 33 GET STARTED TUTORIAL LPDC This window has to be used in case of need to insert more components to the tree such as more parts of the mould or cores On the example shown there are only two layers the whole mould and the part so there is no need to create a new foundry component In Figure H 19 we can also see the Use coating checkbox If we use this option we can change the conductivity and the thickness for the specific coating we are using Now click on the Edit button this window will open Fluid Thermal Phase Change Mechanical Temperature independent date Latent heat U kg 4 30518E 4 Liquidus temperature C 61 Temperature dependent dota Figure H 20 Editing material properties Here we can see the material properties in both table and graphical views We can change these data add new materials etc
12. step 20 771 Contour Fill of TEMPERATURES Figure F 43 Temperature evolution In this result we can animate and see the temperature evolution in the casting surface but it would be interesting to cut the casting and see the temperature inside To do so we will make a cut of the casting and mould Go to Vulcan results Temperature in cut Select Cut xz plane button and then draw a line dividing the mould horizontally in two equal halves The result will be GET STARTED TUTORIAL GRAVITY CASTING V Results View Automatic Limits l Deformation Y Cut plane Endless MV Delay 200 ms Cut xy plane Cut xz plane Cut yz plane Step j 3 8161 Close 28 es 09 0 SOLID TEMPE Defaut Resize 1499 8 1335 2 1170 6 1006 841 37 676 77 512 16 347 56 182 95 18 343 step 13 58161 Contour Fill of TEMPERATURES Figure F 44 Temperature in cut On the figure we can see the temperature evolution of both the casting and the mould in the Cut xz plane By pressing the Play button on the animate window we can see all the temperature evolution during solidification GET STARTED TUTORIAL GRAVITY CASTING Now we will add a virtual thermocouple in a point in the middle of the casting Go to View results Graphs Point evolution Temperatures And select a point in the middle of the casting Figure F 45 Point selection To select the point first we click
13. these data add new materials etc See the Tutorials for more details Now click Cancel on this window And click Cancel to continue with the example G36 00 GET STARTED TUTORIAL HPDC Step 6 OPERATIONS DEFINITION Now we are going to define the specific operations to be simulated Let s click on the Operations icon The following window will appear Figure G 21 Define operations Available operation type Figure G 21 Operations definition ___GETSTARTEDTUTORIAL HPDC 8 From the point of view of casting simulation we can divide the casting process into three parts filling solidification and cooling The filling begins when the material starts to enter into the mould and finishes when the molten metal fills the entire mould At this moment solidification starts as metal begins to cool down and solidify solidification finishes when the last part of the casting turns into solid phase At this moment cooling starts and goes all the way down until the casting and mould reaches room temperature In our gravity casting example we are going to run a simulation the filling and solidification parts of the process Click on the add operations icon The following window will appear Add a new operation Name Filling Select operation type Cycling Filling Thermal solidification Thermo Mechanical solidification Mechanical Cancel Here we have to select all the operations we want to
14. 7 Choose Rotation from the Transformation menu and Lines from the Entities Type menu 8 Enter an angle of 60 degrees and click on Two dimensions 1 This option is also found in the VULCAN Toolbox Pressing the ESC key is equivalent to pressing the center mouse button 10 11 VULCAN TUTORIALS Enter point 200 0 0 in First Point This is the point that defines the center of rotation Click Select to select the first line to be drawn After making the selection press ESC or Finish in the Move window to indicate that the selection of lines to rotate is finished The result is shown in Figure 3 Figure 3 Creating the axes U Copy Entities type Lines z Transformation Rotation z Angle 60 Degrees First point Num x 200 0 2 y 0 0 z 00 V Two dimensions Second point Num x 10 0 y 0 0 gt z 0 0 Duplicate entities Do extrude No z E E V Maintain layers Multiple copies 1 Select Cancel Figure 4 The Copy window C 6 VULCAN TUTORIALS 2 2 Creating the tangential center STEP 2 1 D Choose the option Line located in Geometry gt Create gt Line On the mouse menu choose Contextual and use Join C a or tap Ctrl A to select points 0 0 and 0 25 Press ESC In the Copy window choose Rotation from the Transformation menu Lines from the Entities Type menu and Two dimensions Enter an angle of 120 degrees and select the point 0 25 0 thus rota
15. 9 2 Repeat the rotating and copying process from section 2 5 for the two auxiliary lines Select the option Lines from the Entities type menu and enter an angle of 36 degrees 3 Select the lines to copy and rotate Do this by clicking Select in the Copy window 4 Press ESC to indicate that the process of selecting is finished thus executing the task See Figure 7 Figure 7 Result of copying and rotating the line 5 Rotate the line segment that goes from the origin to point 40 0 an angle of 33 degrees and copy it See Figure 8 Figure 8 Result of the rotations and copies Copy Entities type Lines z Transformation Rotation Ne Angle 36 Degrees First point Num x 0 0 y 0 0 z 00 V Two dimensions Second point Num x 10 0 y 10 0 z 10 0 Duplicate entities Do extrude No m V Maintain layers Multiple copies 1 Select Cancel Figure 9 The Copy window Ja NOTE In the Copy and Move windows the option Pick may be used to select existing points with the mouse B 10 2 Intersecting lines 1 Choose the option Geometry gt Edit Intersection Lines Select the upper circle resulting from the 36 degree rotation executed in section 2 5 Select the line resulting from the 33 degree rotation executed in section 2 6 See Figure 10 The intersection has created a point Figure 11 Press ESC to conclude the intersection of lines Crea
16. F 611 Data Workshop Calculate Help Unstructured ae D m z s S Cartesian PL Hii E Boundary layer Mesh criteria Reset mesh data Draw 2 Generate mesh Figure F 6 Mesh generation screen GET STARTED TUTORIAL GRAVITY CASTING The automatic assigned size of the mesh is 6 change this value to 2 5 and click OK The result will be like this f Figure F 7 Non uniform triangle mesh We can see in Figure F 7 that elements are not too uniform in order to be acceptable Let s decrease the size of the elements to obtain a more uniform mesh Go to Mesh Generate Mesh And set a mesh size of 1 Mesh generation Enter size of elements to be generated Get meshing parameters from model OK Cancel J4 NOTE We can change between geometry view and mesh view by clicking on the icon and also change normal view to render view by right clicking on the geometry and selecting Render Flat or Render Normal GET STARTED TUTORIAL GRAVITY CASTING The result should be like in Figure F 8 O Mesh generated Num of Triangle elements 64654 Num of nodes 32312 Figure F 8 Mesh generation GET STARTED TUTORIAL GRAVITY CASTING Compare the results of Figure F 72 and Figure F 8 and look for example in Figure F 8 the sizes of elements in the upper part of the casting the small cylinder entrance of material We can see there how the
17. Foundry comps Strategy Contacts HTC Env Special Output AX Therman HTC environment properties Identifier Foundry component HTC environment eo Par Env Part HTC Aluminium Mould Env Mould HTC Graylron Add Modify HTC environment curve Component HTC environment curve C New Database bd x Current HT C Env Figure H 24 HTC Environment label Let s have a look on Figure H 24 Here we set the value of heat transfer coefficient with environment HTC Env in this case environment is the air at the temperature set on the problem definition To continue with the example leave all the default options and continue to the next label Tg NOTE f We can modify or create a new value for this parameter by entering on the Edis button and setting a new value The parameter could change for example if the air is not still there is air circulation with fans 40 GET STARTED TUTORIAL LPDC Define operations Filling Foundry comps Strategy Contacts HTC Erw Special Output NN QA Thermal Filling results Output frequency 1 0 Figure H 25 Special Output label In Figure H 25 we define the number of results to be written during the analysis Leave the default option 41 GET STARTED TUTORIAL LPDC Now change to Thermal1 operation on the operations tree as shown in Figure H 26 Define operations Foundry comps Strategy Contacts HTC Env Special Output Availa
18. Remaining Time oh oh im 16 17 m 55 STEP 23 TIME 0 31910E 02 L2_VELOC 0 285E 01 NUM ITERS FILLED VOLUME 0 391512E 04 CPU_TIME 0 803561E 02 Elapsed Time o is im 20 Estimated Remaining Time 7 h h 17 m 24 STEP 24 TIME 0 34678E 02 L2_VELOC 0 307E 01 NUM ITERS FILLED VOLUME 0 417590E 04 CPU_TIME 0 840845E 02 Elapsed Time Estimated Remaining Time STEP 25 TIME 0 37389E 02 Figure G 34 Output view ___GETSTARTEDTUTORIAL HPDG Z o o o y G5 TERMINATE PROCESS If we want to change parameters and calculate again we would click on the last icon This icon will terminate the process In the example we will leave the computer calculating and wait for the end of calculation We will not click on the icon Exiting Vulcan while is still calculating When the pre process is over and we are calculating a process we can exit Vulcan application but without interrupting the calculation Dialog window Are you sure you want to terminate the process borrar started at Mon Apr 23 12 47 06 Figure G 35 Exiting Vulcan while is still calculating Click No and Vulcan will exit We can open Vulcan later during or after the calculation The computer of course must remain on GET STARTED TUTORIAL HPDC Step 9 POST PROCESS Post process means the visualization of the simulation results this is perhaps the most important step of all the casting simulatio
19. STE B 1 Select the ok layer by double click From now on all entities created will belong to the ok layer 2 Choose the option Line located in Geometry gt Create gt Line 3 Enter the following points 0 11 8 11 8 31 11 31 11 11 and 15 11 Press ESC to indicate that the process of creating lines is finished Figure 8 Profile of one of the disks around the pipe 4 From the Copy window choose Lines and Translation A translation defined by points 0 11 and 15 11 will be made In the Multiple copies option enter 8 the number of copies to be added to the original Select the lines that have just been drawn Figure 4 The profile of the disks using Multiple copies VULCAN TUTORIALS C 9 5 Choose Line located in Geometry Create gt Straight Line Select the last point on the profile using the option Join C a which is in Contextual on the mouse menu Now choose the option No join C a Enter point 200 11 Press ESC to finish the process of creating lines 6 Again choose the Line option and enter points 0 9 and 200 9 Press ESC to conclude the process of creating lines Figure 10 HES Figure 5 Creating the lines of the Figure 11 Copy of the vertical line profile segment starting at the origin of coordinates 7 From the Copy window choose Lines and Translation As the first and second point of the translation enter the points indicated in Figure 11 Click Select a
20. absolute 0 00e 000 Minimum element size 0 00e 000 Sphere mesher Algorithm Radius Expansion Max iterations 500 Others Smoothing Normal z Mesh until end V No mesh frozen layers Avoid elements with all its nodes in boundary Allow quadrilateral dominant meshes Mesh always by default NJ ql Figure G 5 Meshing preferences Click Accept and then Close the window Geo GET STARTED TUTORIAL HPDC It is recommendable to first generate a triangular surface mesh in order to generate a good tetrahedral 3D mesh because this way we can check the mesh quality faster The steps to generate a good tetrahedral mesh will be e Generating a surface mesh e Check the quality of the mesh generated and make corrections if necessary e Return to geometry view and generate a geometrical volume out of the casting surfaces e Generate a tetrahedral mesh of the casting overwriting the previous mesh e Check again for mesh quality e Return to geometry and generate the mould volume and then generate the final casting and mould mesh overwriting the previous mesh this is the only mesh needed the previous ones were generated for verification Save the project before meshing Go to File Save as Go to the Mesh menu as shown in Figure G 6 tilities Data Workshop Calculate Help cast Unstructured gt eS yz Structured gt od ie te 8 6S Ele
21. c Select all the points of the mould with a selection window Figure F 13 Selection window d Inthe command line the following message will be displayed Added 8 new points to the selection Enter more points ESC to leave These are all the points added to the selection the points are added and as it says in the command line we have to press Esc to accept the selection and leave The following message will appear in the command line Assigned size 7 to 8 new entities e click Close to close the enter value window Now we repeat points a to e for lines and surfaces with the same size of 7 wy Once done we repeat points a to e for volumes with size 5 We can use the button gt to assign the sizes directly to points lines and surfaces it will be assigned to all the active points lines and surfaces Once the sizes are all assigned we generate the mesh again same general mesh size 1 The result shall look like this Figure F 14 GET STARTED TUTORIAL GRAVITY CASTING Dialog window WW Mesh generated Num of Tetrahedra elements 218365 Num of nodes 37670 w i We Rg Ny Figure F 14 Generated mesh Now that the mesh is generated we will see in detail how to set the process parameters for this particular type of problem gravity casting We will continue the step by step process with the Process bar GET STARTED TUTORIAL
22. click OK and then enter on the same previous icon and select Thermal solidification operation 36 GET STARTED TUTORIAL LPDC The result should look like this Define operations illi Foundry comps Strategy Contacts HTC Env Special Output AY Therman Available foundry components Selected foundry components Mould Part Figure H 22 Operations definition In Figure H 22 we can see that all the foundry components are assigned by default to the filling and solidification operations In Figure H 17 we created those foundry components Here we have the option of changing the foundry components selecting different components for different operations etc To continue with the example we leave the default selection and then we are going to view and set all the parameters for both operations We have to go trough all the labels and change the default parameters for those of interest In our example we will see all the options and a short explanation of the principal parameters 37 GET STARTED TUTORIAL LPDC In strategy label Figure H 29 we set the parameters for the low pressure die casting process and we decide whether to use tilt pouring or not In case of using tilt pouring we have to select it and enter all the options In the figure we can see that we have to set some parameters of the filling process we have to enter the distance between the free surface of the crucible and the end of t
23. for the mould Go to Create volume and select all the surfaces with a selection window ig NOTE We can use the Layers icon to facilitate the selection of the casting surfaces Leave the cast layer on and the mould layer off for this selection 20 GET STARTED TUTORIAL LPDC Figure H 9 Mould volume generation Now zoom on the small circle material entrance and click on the small surface in order to deselect it The result should look like this Figure H 10 Mould volume generation Now press Esc twice and the mould volume will be generated 21 GET STARTED TUTORIAL LPDC Assigning mesh size to the mould In the case of the mould geometry we will try to use tetrahedral elements as big as possible in order to reduce the total number of finite elements of the problem This will reduce the calculation time so instead of assigning an automatic size of 2 to all the geometry cast mould we are going to do the following Turn off the layer cast Figure H 11 Mould layer And now we will see in detail how to assign properties to the mesh 22 GET STARTED TUTORIAL LPDC Using the assign mesh sizes icon we will assign properties to the geometrical entities of our geometry We have to assign mesh sizes in geometrical hierarchy order Points Lines Surfaces and Volumes Let s assign a mesh size of 10 to all the entities of the mould a Click on the first icon Bee The following window will
24. i Ty PA rt i 3 i he i hs M i ger ul f I a Vi all P iT ess a fat Se T E art Ea a ee aa oa E po T 7 i he n te ae aN Ai i a we I I ae P as ina a a a H ik a BEX Figure F 8 Gravity casting geometry GET STARTED TUTORIAL GRAVITY CASTING The geometrical entities in Vulcan have the following hierarchy order Points gt Lines gt Surfaces gt Volumes We can interpret the hierarchy by higher entities and lower entities For example a surface is higher than a line a surface is lower than a volume etc we cannot delete a surface if there are related higher entities present Volumes In Figure F 8 we can see the points in black lines in blue and surfaces in pink There are always points that define line ends lines that define surfaces etc Now that we have a geometry to work with let s begin with the next step geometry treatment GET STARTED TUTORIAL GRAVITY CASTING Step 2 GEOMETRY TREATMENT This geometry apparently has no errors so we won t collapse points or lines Let s check the integrity of the geometry by selecting Draw higher option Files View Geometry Utilities Data Mesh Wo OB BIBAIOSes OO Be RE HigherEntities a Other 2 Interior Figure F 9 Draw Higher screen GET STARTED TUTORIAL GRAVITY CASTING In Figure F we can check the geometrical integrity of the model before we mesh it To form a closed surface all t
25. independent data Latent heat 2 78427E 5 Solidus temperature 1375 0 Liquidus temperature 1458 0 Temperature dependent data Material properties Solid fraction Z Table Graph Table Graph Points Temperature Value Ye Temperature vs solid fraction 1376 0 0 9777 1380 0 0 7994 1381 0 0 7755 1390 0 0 7475 1400 0 0 7071 1410 0 0 6472 1420 0 0 5769 1430 0 0 4871 1440 0 0 3676 1450 0 0 189 1458 0 0 0 1375 1389 1403 147 1430 1444 1458 Add to database Cancel Figure F 21 Editing material properties Here we can see the material properties in both table and graphical views We can change these data add new materials etc See the Tutorials for more details Now click Cancel on this window And click Cancel to continue with the example GET STARTED TUTORIAL GRAVITY CASTING Step 6 OPERATIONS DEFINITION Now we are going to define the specific operations to be simulated Let s click on the Operations icon The following window will appear Figure F 227 Define operations Available operation type he as software for casting process optimization ka a Figure F 22 Operations definition GET STARTED TUTORIAL GRAVITY CASTING From the point of view of casting simulation we can divide the casting process into three parts filling solidification and cooling The filling begins when the material starts to enter into the mould and finishes when the mol
26. mesh quality is improved Let s now return to geometry by clicking and generate the volume and tetrahedral elements Go to Geometry Create Volume By contour or click the Create volume icon l The following will appear in the command line Enter surfaces to define volume ESC to leave Select all the surfaces of the casting with a selection window Added 108 new surfaces to the selection Enter more surfaces ESC to leave press Esc Created 1 new volume Enter more volumes And now press Esc again Leaving volume generation Now regenerate a mesh with size of 1 in order to obtain a mesh of the volume The result will look again as in Figure F 8 Generating the mould mesh Return to geometry view Click on Layers icon and turn on the layer mould With the layer mould selected double click on the layer mould Now we will generate a volume for the mould Go to Create volume and select all the surfaces with a selection window ig NOTE We can use the Layers icon to facilitate the selection of the casting surfaces Leave the cast layer on and the mould layer off for this selection GET STARTED TUTORIAL GRAVITY CASTING Figure F 9 Mould volume generation Now zoom on the small circle material entrance and click on the small surface in order to deselect it The result should look like this Figure F 105 Mould volume generation Now press Esc twice and the mould volume
27. mesh size to the mould In the case of the mould geometry we will try to use tetrahedral elements as big as possible in order to reduce the total number of finite elements of the problem This will reduce the calculation time so instead of assigning an automatic size of 5 to all the geometry cast mould we are going to do the following Turn off the layer cast Figure G 11 Mould layer And now we will see in detail how to assign properties to the mesh Gea GET STARTED TUTORIAL HPDC Using the assign mesh sizes icon we will assign properties to the geometrical entities of our geometry We have to assign mesh sizes in geometrical hierarchy order Points Lines Surfaces and Volumes Let s assign a mesh size of 30 0 to all the entities of the mould a Click assign sizes to points the first icon The following window will open ceremony a 7 Enter size to assign to points 0 0 to unassign Close Figure G 12 Mesh generation ___GETSTARTEDTUTORIAL HPDG _ O Z O o o Y OG b Assign a size of 30 in the window and click the Assign button c Select all the points of the mould with a selection window Figure G 13 Selection window d Inthe command line the following message will be displayed Added 8 new points to the selection Enter more points ESC to leave These are all the points added to the selection the points are added and as it says in the comm
28. meshed without distortion We can compare the results of Figure D 16 with the previous mesh Figure D 7 to Figure D 10 VULCAN TUTORIALS E GEOMETRY CORRECTION The objective of this tutorial is to see how VULCAN imports files created with any other CAD software The imported geometry may contain imperfections that must be corrected before generating the mesh For this study an IGES formatted geometry representing a casting is imported These steps are followed e Importing an IGES formatted file to VULCAN e Correcting errors in the imported geometry e Generating the correct mesh VULCAN TUTORIALS This page is intentionally left blank VULCAN TUTORIALS 1 IMPORTING AN IGES FILE VULCAN is designed to import a variety of file formats Among them are standard formats such as IGES DXF Parasolid or VDA which are generated by most CAD programs VULCAN can also import meshes generated by other software in NASTRAN or STL formats The file importing process is not always error free Sometimes the original file has incompatibilities with the format required by VULCAN These incompatibilities must be overcome manually This example deals with various solutions to the difficulties that may arise during the importing process 1 1 Importing an IGES file 1 Select Files gt Import IGES 2 Select the IGES formatted file tutorial_importi5 igs and click Open This file can be downloaded from the VULCAN web page htip Awww
29. octagon 1 Create a point 10 0 Choose GeometryCreate gt Point and enter the coordinates in the command bar Press ESC to conclude the insertion of the point 2 Inthe Copy window select Points and Rotation Enter an angle of 45 degrees and select the two dimensions option In the option Multiple Copies enter 2 3 Select the tool Line Select three consecutive points to create two sides of the octagon with Join C a located in Contextual on the mouse menu Press ESC to close the tool Line See Figure 17 Figure 17 Creating the Figure 18 Symmetry Figure 19 Symmetry first quadrant relative to the vertical axis relative to the horizontal AXIS VULCAN TUTORIALS B 15 3 2 Creating the rest of the octagon by mirror effect 1 Inthe Copy window choose Lines and Mirror Be sure the option Two Dimensions has been selected 2 Enter two points that define a vertical axis of symmetry for example 0 0 0 and 0 10 0 3 Choose Select and select the two sides of the octagon that have been drawn Press ESC to conclude the selection Figure 18 4 Repeat the process entering two points that define a horizontal axis of symmetry for example 0 0 0 and 10 0 0 This time select the four sides of the octagon Figure 19 3 3 Creating a hole in the surface of the mechanical part 1 Choose the option Geometry Edit Hole NURBS Surface 2 Select the surface in which to make the hole Figure 20 3 Select the lines that define th
30. on Select Nodes in the right menu on the Vulcan screen because we will plot the temperatures in a node of the mesh then we have to click once in the zone shown in Figure F 45 for example Once there is a red point signalled we press Esc The result will be GET STARTED TUTORIAL GRAVITY CASTING TEMPERATURES TIME_STEP Figure F 46 Virtual thermocouple in the casting Once finished to View results No graphs and then View results No results GET STARTED TUTORIAL GRAVITY CASTING In the previous temperature images we cannot see the casting phase change from liquid to solid In order to see this and for example the effectivity of our riser system the evolution of the solid phase the last points in the casting to reach solid state etc we will do the following Go to Vulcan results Solid fraction evolution Figure F 47 Solid fraction evolution Here we have the liquid fraction of the casting is plotted in red and the solid part of the casting disappears while is forming so we only see the remaining liquid parts inside the casting as it solidifies during the animation The last points remaining in red should be the risers GET STARTED TUTORIAL GRAVITY CASTING Finally we will plot the solidification modulus of our casting The modulus is the volume to surface ratio of the casting and it can also be seen inside the casting by making cuts Let s go back to Figure F 43 and make ag
31. open 2 Enter size to assign to points 0 0 to unassign Figure H 12 Mesh generation 23 GET STARTED TUTORIAL LPDC b Assign a size of 7 in the window and click the Assign button c Select all the points of the mould with a selection window Figure H 13 Selection window d Inthe command line the following message will be displayed Added 8 new points to the selection Enter more points ESC to leave These are all the points added to the selection the points are added and as it says in the command line we have to press Esc to accept the selection and leave The following message will appear in the command line Assigned size 10 to 8 new entities e click Close to close the enter value window Now we repeat points a to e for lines surfaces and volumes with the same size of 7 Once the sizes are all assigned we generate the mesh again Same general mesh size 2 The result shall look like this Figure H 19 24 GET STARTED TUTORIAL LPDC W Mesh generated Num of Tetrahedre elements 67005 Num of nodes 12395 Figure H 19 Generated mesh Now that the mesh is generated we will see in detail how to set the process parameters for this particular type of problem low pressure die casting We will continue the step by step process with the Process bar 25 GET STARTED TUTORIAL LPDC Step 4 FOUNDRY PROCESS DEFINTION Until now we were dealing with
32. parameters like temperature of front encounters early cooling during filling and possible solidification during filling To see this kind of results we will go to Vulcan results Temperature evolution or press the button F TEMPERATURES 1500 1497 6 1495 2 1492 9 1490 5 1486 1 1465 7 1483 3 1481 1476 6 step 0 470615 Contour Fill of TEMPERATURES Figure F 41 Temperature evolution during filling Here we can see the temperatures and the temperatures colour scale and also the time step since the start of filling GET STARTED TUTORIAL GRAVITY CASTING Now we will load the second foundry operation we had run solidification Solidification goes from the end of filling until the casting is completely solid Let s see the results Go to Vulcan results Load results and load the Thermal operation U Load results Load from Select f Operation Select operation Operations Thermal Load file File Cancel Figure F 42 Thermal operation loading Once the results are loaded click Ok and let s see some solidification results This time we will see temperature evolution in both casting and mould excess temperature on the cores etc Go to Vulcan results Temperature evolution or press the button GET STARTED TUTORIAL GRAVITY CASTING The result will be like this TEMPERATURES 1399 3 1298 5 1197 8 1097 996 28 695 54 794 6 694 05 593 31
33. result 8 Visualize filling time result 9 Visualize thermal temperature evolution result 10 Visualize solid fraction result 11 Plou with a plane the temperature result 12 Visualize the temperature evolution with graphs 13 View process info Le 14 Reload the results l 15 Calculate rise from modulus These icons are placed in a logical order 1 Load results 2to8_ Filling results GET STARTED TUTORIAL GRAVITY CASTING 9 10 11 12 15 Thermal results 13 14 Process info Let s begin by opening Vulcan and then with the step by step guided tutorial On the computer Desktop double click on the Vulcan icon the main screen will show up vem a OB BB F1VBives Zai 29 0 ma OS Ow Fl ee OOZI SCIl6 6 E GP Ka Gear a Pi Daa Netw Fiet SQ RO MHKHSRX AP PAP BoAW UY Postpeocess finishe Sure leenang postprocess WESC Command a lel Figure F 2 Vulcan main screen Once Vulcan is opened go to the main menu and click on Data Problemtype Vulcan GET STARTED TUTORIAL GRAVITY CASTING The following window will appear Figure F 3 If the window doesn t appear you can go directly to Step 1 You are going to load problemtype Vulcans what do you want bo do f Update to new problemtyoe All data information materials conditions data will be lost Transform to new problemtype Data will be converted to new problemtype if possible Some data may be lost Cance
34. result will be SOLIDIF MODULUS 0 0093011 0 0082676 0 0072342 0 0062007 0 0051673 0 0041338 0 0031004 0 0020669 0 0010335 pl Figure G 46 Solidification modulus H LPDC LOW PRESSURE DIE CASTING SIMULATION USING VULCAN Version 10 0 GET STARTED TUTORIAL LPDC This page is intentionally left blank GET STARTED TUTORIAL LPDC INTRODUCTION In this tutorial we will follow an entire step by step procedure in order to run a low pressure die casting simulation using Finite Element Analysis with Vulcan We will import an IGES geometry into Vulcan s graphical interface mesh it set the process parameters and finally get simulation results temperatures velocities turbulences porosity defects etc Basically a Finite Element Analysis consists of three phases e Pre process e Calculation e Post Process During the pre process phase we will completely define the problem geometry set the types of analyses to perform and establish the physical properties of the materials temperatures etc Once the problem is completely defined we will launch the calculation the total calculation time will depend on the complexity of the problem this is the number of elements in both the casting and the mould During the calculation time user s participation is not required The calculation will let us know when is finished When calculation is finished the user can start the post processing phase
35. results Solid fraction evolution or select the button Figure H 44 Solid fraction evolution Here we have the liquid fraction of the casting is plotted in red and the solid part of the casting disappears while is forming so we only see the remaining liquid parts inside the casting as it solidifies during the animation The last points remaining in red should be the risers 62 GET STARTED TUTORIAL LPDC Finally we will plot the solidification modulus of our casting The modulus is the volume to surface ratio of the casting and it can also be seen inside the casting by making cuts Let s go back to jError No se encuentra el origen de la referencia and make again the temperature evolution and then again temperature in cut Once we have the results like in Figure H 41 go to View results Contour fill Solidif Modulus The result will be SOLIDIF MODULUS 0 0060402 0 0052852 0 0045301 0 0037751 0 0030201 0 0022651 0 00151 0 00075502 ol Figure H 45 Solidification modulus 63
36. results loaded let s begin for example to see the evolution of the casting material in the mould where there could be air entrapment or the advancing fronts of material could encounter the last spots of the mould to be filled etc To see this we will use a tool called filling mater In this animation we will see the material free surface in red the filled areas in grey and the mould will be transparent Go to main menu Vulcan results Filling mater Once the Animate window appears press the Play button M Results View Static Automatic Limits analysis Deformation animation profile Endless I From step 1 to step 65 Set duration by TotalTime 5 s l use step values as scaler C Delay between steps 76 ms Use step values as seconds Step number 47 Step value 0 218C00 0 47 1i 9000 Save TIFF vy on x l Save MPEG xor T Create a stereoscopic animation Default v Resize Close Figure H 37 Filling mater animation In Figure H 37 we can see the Animate window and the control buttons We can keep this window open while we rotate zoom in and zoom out the casting Let s explain the basic Animate controls 53 GET STARTED TUTORIAL LPDC Basic Animate window controls Delay We can set this time in order to slow down the animation delay time is not the real time but a time we can increase in order to ease the visualization Step This box shows the real time step It
37. s move on to the next step 15 GET STARTED TUTORIAL LPDC Step 3 MESH GENERATION Before start the meshing generation we will set the Meshing parameters as shown in jError No se encuentra el origen de la referencia Go to Utilities Preferences and select the label Meshing Set all the parameters as shown in the figure Preferences General Graphical Meshing Exchange Fonts Format Grid Quadratic type Normal Quadratic Quadratic9 Unstructured mesher Surface RFast RSurf Volume Advancing front Delaunay Isosurface Automatic correct sizes C None Normal Hard Unstructured size transitions V Regular transition near boundary Chordal error Maximum chordal error in model relative 0 0 absolute 1 00e 000 Minimum element size 1 00e 000 Sphere mesher Algorithm Radius Expansion v Max iterations 500 Others Smoothing Normal Ed V Mesh until end V No mesh frozen layers Avoid elements with all its nodes in boundary Allow quadrilateral dominant meshes Mesh always by default al NI ql Figure H 5 Meshing preferences Click Accept and then Close the window 16 GET STARTED TUTORIAL LPDC It is recommendable to first generate a triangular surface mesh in order to generate a good tetrahedral 3D mesh because this way we can check the mesh quality faster The steps to generate a good tetrahedral mesh will be e Generating a surf
38. shows the time in seconds since the filling process had begun Then we have the animation controls Sooo these controls are the standard Play Pause Stop Fast Forward Rewind controls We can control the evolution of the animation with them Once the filling mater analysis is done go to View results No results 54 GET STARTED TUTORIAL LPDC Let s say now that we want to see other phenomena for example turbulences formation highest filling velocities inside the casting velocities at which the advancing fronts encounter etc We will use a different representation to see these results Go to Vulcan results Filling vectors And again the animate window will show up The animation will show the velocity vectors inside the casting VELOCITIES m s 1 2155 Z 1 0805 0 94541 0 81035 0 67529 0 54023 0 40518 0 27012 0 13506 0 Figure H 38 Filling vectors animation The colour scale represents the module of velocity In Figure H 38 we can see the highest velocities in red and the lowest velocities in blue Once finished with filling vectors go to View results No results 55 GET STARTED TUTORIAL LPDC Now we want to see parameters like temperature of front encounters early cooling during filling and possible solidification during filling To see this kind of results we will go to Vulcan results Temperature evolution Figure H 3
39. simulation results Once the calculation is finished we can visualize the results of this simulation There are many different ways to do it like colour maps vectors iso surface curves virtual thermocouples etc Figure H 35 shows the window that appears once calculation step is finished we can directly access to post process by clicking on Postprocess buiton Process window Project Starttime UID Priority Process info A Process part2 started at Tue Apr gt 24 12 54 45 has finished Postprocess Output view Terminate Close Remote Start remote Start Figure H 35 Process info Another way to switch between pre and post process is by clicking the toggle icon S Ja NOTE Every time we toggle when we return to post process we have to load the results 51 GET STARTED TUTORIAL LPDC The first step in results visualization is to load results of any foundry operation Filling thermal solidification thermo mechanical solidification Lets load the filling operation and analyze the results Go to Vulcan results Load results And select the Filling1 operation Load results Load from Select Operation C File Select operation Operations Filling v Load file File Cancel Figure H 36 Results loading Click Ok and the filling results will be loaded 52 GET STARTED TUTORIAL LPDC Now that we have all the filling
40. this is the results loading view and analysis this is the objective of the finite element simulation This tutorial consists of 9 steps that will guide you trough all the low pressure die casting simulation process Before we start let s describe Vulcan 10 0 interface If you have previously worked with the new interface you can skip Step 0 and continue to the next section Tg NOTE The low pressure die casting is the process in which gas pressure is injected into the crucible and the filling material goes up trough a refractory stalk often used in the production of automobile wheels axysymmetric parts etc GET STARTED TUTORIAL LPDC Step 0 THE PROCESS BAR Vulcan has a process bar that will guide us trough all the preparations settings and calculation of our casting process This process bar is normally located on the left side of the screen PP Vulcan x64 Files View Geometry Utilities Data Mesh Workshop Calculate Help CO DIBA QVSirou LZ aO Pine 6 1 T PAA BBS 7 Si y i kA a RE SURO KK S Me Figure H 1 The process bar ig NOTE If not present you can activate the Process bar from the menu Utilities Tools Toolbars and also change its position to top bottom right etc GET STARTED TUTORIAL LPDC Process bar icons LE 1 IGES read A a 2 Collapse entities Mesh properties 4 Define the main process characteristic 5 Define foundry components
41. top bottom right etc GET STARTED TUTORIAL HPDC G 5 Process bar icons E 1 IGES read ma n 2 Collapse entities Mesh properties 4 Define the main process characteristic 5 Define foundry components 6 Define operations 7 Save the project 8 Calculate 8 1 Process info 8 2 Kill the process These icons are placed in a logical order 1to6 Pre process 7 Save the project before calculate 8 Calculation We can completely define and calculate the casting component under study using this bar and in case necessary interrupt the calculation by clicking icon 8 2 Let s begin by opening Vulcan and then with the step by step guided tutorial G ET STARTED TUTORIAL HPDC On the computer Desktop double click on the Vulcan icon the main screen will show up te help aa OC BIBAIQS x0 Zahn aA a icar I ERE AEE A E Q Ka Geama a Fi Data Nedng a Filet 4 View 4 Ute al Layers a Paspocari gt Qua JGR B4BT arcape f2 Name clyo Fult B _ 2 Layer E e ae A 5 i BT XK X w a y 7 w Pastpeocess finished aj Sure leaning postpracess WESC eee oe Command a Figure G 2 Vulcan main screen Once Vulcan is opened go to the main menu and click on Data Problemtype Vulcan ___GETSTARTEDTUTORIAL HPDC ooo y y Y OG The following window will appear Figure G 3 If the window doesn t appear you can go directly to Step 1 U Select
42. user does not choose option Duplicate entities point 6 will be merged with point 5 when the entities are copied By labeling the entities we could verify that only one point has been created VULCAN TUTORIALS A 13 Finishing the copy command for the surface we obtain the following surfaces Now we can generate the volume delimited by these surfaces To create the volume simply select the command Geometry gt Create gt Volume gt By contour This option is also available in the toolbar Select all the surfaces Vulcan automatically generates the volume of the cube The volume viewed on the screen is represented by a cube with an interior color of sky blue A 14 VULCAN TUTORIALS Before proceeding with the mesh generation of the volume we should eliminate the information of the structured mesh created previously for the surface Do this by selecting Mesh gt Reset mesh data and the following dialog box will appear on the screen Dialog window Sure you want to reset all meshing information Cancel In which the user is asked to confirm the erasure of the mesh information Ja NOTE Another valid option would be to assign a size of 0 to all entities This would eliminate all the previous size information as well as the information for the mesh and the default options would become active Next generate the mesh of the volume by choosing Mesh gt Generate mesh Another Auxiliary Window appears into which the size of t
43. we are going to visualize on the post process In the example leave Temperature Solid fraction Solidification modulus Solidification time Porosity and Macro Porosity Now that we have defined all the problem parameters click on the Close button The parameters will be saved GET STARTED TUTORIAL GRAVITY CASTING Step 7 SAVE PROJECT Before start the calculation don t forget to save the project Click on Save icon Tg NOTE the filename must not contain spaces or symbols Step 8 CALCULATION UT Vuican Project borers E Files View Geometry Utilities Data Mesh Workshop Calculate Help O8 BISSEMVIBAlVS Lge G 1 eZAIDPQLDQVEWUZRLAKBBERAH ie igs i M IZ AGE Y t Save project CW Calculate Ouptput view Smn OIS Kill process Figure F 33 Calculate Output view and kill Process icons GET STARTED TUTORIAL GRAVITY CASTING Now following the column of icons shown in Figure F 33 we first saved the project and then Calculate it The calculation time will depend upon the complexity of the problem The calculation window will look like this Calculate the simulation Calculate General options Solver accuracy Low Medium High Select operation ee Calculated operations From operation Filling Name To operation k Figure F 39 Calculation window Select From operation filling To operation Thermal1 and click OK The calculation wil
44. we toggle when we return to post process we have to load the results GET STARTED TUTORIAL GRAVITY CASTING The first step in results visualization is to load results of any foundry operation Filling thermal solidification thermo mechanical solidification Let s load the filling operation and analyze the results ra Go to Vulcan results Load results or select And select the Filling1 operation Load from Select Operation Select operation Operations Filling z Load file File Cancel Figure F 38 Results loading Click Ok and the filling results will be loaded GET STARTED TUTORIAL GRAVITY CASTING Now that we have all the filling results loaded lets begin for example to see the evolution of the casting material in the mould where there could be air entrapment or the advancing fronts of material could encounter the last spots of the mould to be filled etc To see this we will use a tool called filling mater In this animation we will see the material free surface in red the filled areas in grey and the mould will be transparent Go to main menu Vulcan results Filling mater or press the button S Once the Animate window appears press the Play button NM Results View Static analysis l Deformation animation profile l Endless M Automatic Limits I From step 1 to step 96 Set duration by Total Time 5 S F use step values as scaler C Del
45. will be generated GET STARTED TUTORIAL GRAVITY CASTING Assigning mesh size to the mould In the case of the mould geometry we will try to use tetrahedral elements as big as possible in order to reduce the total number of finite elements of the problem This will reduce the calculation time so instead of assigning an automatic size of 1 to all the geometry cast mould we are going to do the following Turn off the layer cast Figure F 11 Mould layer And now we will see in detail how to assign properties to the mesh GET STARTED TUTORIAL GRAVITY CASTING Using the assign mesh sizes icon we will assign properties to the geometrical entities of our geometry We have to assign mesh sizes in geometrical hierarchy order Points Lines Surfaces and Volumes Let s assign a mesh size of 7 0 to the points lines and surfaces of the mould and a size of 5 0 to the mould s volume a Click on assign sizes to points the first icon EAI The following window will open 0 Layers z C Name vo Fu Tr B cast ts D U Enter value window Q Enter size to assign to points 0 0 to F unassign Layer To use Y mould On Off rie r Color Sel New Delete Rename alphabetic To back Send To v Close Figure F 12 Mesh generation GET STARTED TUTORIAL GRAVITY CASTING b Assign a size of 7 in the window and click the Assign button
46. 0 0E 6 Figure F 20 Foundry components definition Click Close to save the changes Tg NOTE Let s explain some of the icons that appear in the Components definition window You can skip this note to continue with the example and go to the Step 6 GET STARTED TUTORIAL GRAVITY CASTING Click again on the icon In case of having multiple layers you can assign and unassign layers to foundry components by using the gt icons for example in case of having the mould divided in upper part and lower part on different layers or in case of having to make changes Now click on the Add new foundry component icon Name Part2 Select a foundry component type Part C Mould C Filing system Chill C Fiter C Feeding system f Core C Cooling system 0 Sleeve Ok Cancel GET STARTED TUTORIAL GRAVITY CASTING This window has to be used in case of need to insert more components to the tree such as more parts of the mould or cores On the example shown there are only two layers the whole mould and the part so there is no need to create a new foundry component In Figure F 20 we can also see the Use coating checkbox If we use this option we can change the conductivity and the thickness for the specific coating we are using Now click on the Edit button this window will open Material properties Material name gt 40CrMoV5 Fluid Thermal Phase Change Mechanical Composition Temperature
47. 9 Temperature evolution during filling TEMPERATURES C 640 637 12 634 25 631 37 628 5 625 62 622 74 619 87 616 99 614 12 Here we can see the temperatures and the temperatures colour scale and also the time step since the start of filling 56 GET STARTED TUTORIAL LPDC Now we will load the second foundry operation we had run solidification Solidification goes from the end of filling until the casting is completely solid Let s see the results Go to Vulcan results Load results and load the Thermal operation Load results Load from Select Operation File Select operation Operations Thermal Z Load file File Cancel Figure H 40 Thermal operation loading Once the results are loaded click Ok and let s see some solidification results This time we will see temperature evolution in both casting and mould excess temperature on the cores etc Go to Vulcan results Temperature evolution 57 GET STARTED TUTORIAL LPDC The result will be like this TEMPERATURES 583 97 531 69 479 42 427 14 374 87 322 6 270 32 218 05 Figure H 49 Temperature evolution In this result we can animate and see the temperature evolution in the casting surface but ti would be interesting to cut the casting and see the temperature inside To do so we will make a cut of the casting and mould Go to Vulcan results Results evolution with graphs or
48. C ores OC B BAIVSe lt 0 Paes OOO mr OS Fell ECO eT OGZ 2cla 6 Bl lt of igs omw EA Daa one ee Meshing Pe Fant n is ayers an fis Uet al K aAaReres eT Postpocwes s D Name cj vol Fuj Tr BI Qu ia Y Layerd v r excape g oat 3 poe asz E Gd Q RO 4H SRA Ad ta a IGES File Read try read Comman d ES Figure H 5 IGES read Close the info window and have a look at the geometry of Figure H 5 by right clicking and doing rotate trackball and zoom in and out Once done with looking at geometry we will start working with different layers one layer for the casting one layer for the mould etc Click on the Layers icon The following window will appear Figure H 6 10 GET STARTED TUTORIAL LPDC Figure H 6 Layers control window Perform the following operations e Click on New button and create a new layer Layer0 Ev Figure H 7 Layer selection and layer to use e Select the layer Layer0O enter the name cast in the textbox and click on Rename button Tg NOTE The selected layer is highlighted in black After selecting a layer by simply clicking on it we can delete it rename it change its color turn it on and off send elements to it etc The layer to use instead is the layer with the checkmark in the layer to use we can create geometry delete it etc in the drawing Summary selected is to make changes using layers windo
49. C environment curve C New Database z x Current HTC Env Figure G 24 HTC Environment label Let s have a look on Figure G 24 Here we set the value of heat transfer coefficient with environment HTC Env in this case environment is the air at the temperature set on the problem definition To continue with the example leave all the default options and continue to the next label J4 NOTE We can modify or create a new value for this parameter by entering on the Edis button and setting a new value The parameter could change for example if the air is not still there is air circulation with fans Gea GET STARTED TUTORIAL HPDC Define operations Foundry comps Strategy Contacts HTC Env Special Output Filling results Output frequency 1 0 F Use clamping forces Figure G 25 Special Output label In Figure G 25 we define the number of results to be written during the analysis Leave the default option In HPDC we can select the clamping forces of the mould during the filling GET STARTED TUTORIAL HPDC G 43 Now change to Thermal1 operation on the operations tree as shown in Figure G 26 Define operations Foundry comps Strategy Contacts HTC Env Special Output Available foundry components Selected foundry components Mould Part Figure G 26 Thermal settings In this screen foundry components are already selected Go to the next scre
50. Create Volume By contour or click the Create volume icon g The following will appear in the command line Enter surfaces to define volume ESC to leave Select all the surfaces of the casting with a selection window Added 173 new surfaces to the selection Enter more surfaces ESC to leave press Esc Created 1 new volume Enter more volumes And now press Esc again Leaving volume generation Now regenerate a mesh with size of 5 in order to obtain a mesh of the volume The result will look again as in Figure G 8 Generating the mould mesh Return to geometry view Click on Layers icon and turn on the layer mould With the layer mould selected double click on the layer mould Now we will generate a volume for the mould Go to Create volume and select all the surfaces with a selection window Tg NOTE We can use the Layers icon to facilitate the selection of the casting surfaces Leave the cast layer on and the mould layer off for this selection G2 GET STARTED TUTORIAL HPDC Rotate the geometry in order to see the material entrance slot Figure G 9 Mould volume generation Now zoom on the slot material entrance and click on the small surface in order to deselect it The result should look like this Figure G 10 Mould volume generation Now press Esc twice and the mould volume will be generated ___GETSTARTEDTUTORIAL HPDC __ oO o o y OG Assigning
51. ED TUTORIAL GRAVITY CASTING U Define operations k Filing Foundry comps Strategy Contacts HTC Eny Special Output SS 2 Sh _ Thermal Filling results Output frequency 1 0 Figure F 27 Special Output label In Figure F 27 we define the number of results to be written during the analysis Leave the default option GET STARTED TUTORIAL GRAVITY CASTING Now change to Thermal1 operation on the operations tree as shown in Figure F 28 Define operations Foundry comps Strategy Contacts HTC Env Special Output Available foundry components Selected foundry components Mould Part Figure F 28 Thermal settings In this screen foundry components are already selected Go to the next screen GET STARTED TUTORIAL GRAVITY CASTING Define operations Foundry comps Strategy Contacts HTC Eny Special Output General parameters Perform de molding De molding only casting De molding all foundry components De molding termination De molding by Time Time value s Casting temperature Temperature value C Termination by C Time Time value s Casting temperature Temperature value C Figure F 29 Thermal Strategy label In this screen we define the De moulding and Termination characteristics of our process In the current problem we leave de moulding deselecte
52. ENT This geometry apparently has no errors so we won t collapse points or lines Lets check the integrity of the geometry by selecting Draw higher option Once the three icon submenu is open click on the Draw Higher icon Files View Geometry Utilities Data Mesh Wor OOS OSes Ole Bl et Ee s show number of higherentities parents in lines The result shall look like this 14 GET STARTED TUTORIAL LPDC HigherEntities a Other 2 Interior Figure H 9 Draw Higher screen In Figure H 9 we can check the geometrical integrity of the model before we mesh it To form a closed surface all the lines need to be the end of two surfaces Interior in the figure If there would be open edges on the geometry the lines would appear under a different colour and labelled Boundary or Isolated lines The lines at the entrance of the material Other are connected to more than two surfaces because they are also connected to the mould surfaces so they have a different colour this is correct The other lines are all interior in red This means that all the lines are connected to two surfaces the lines are not forming open boundaries or are isolated lines In other words this geometry consisting of points lines and surfaces is sound We can rotate and zoom the casting while we are in draw higher mode Now let s press Esc to go back to the geometry We have now a repaired geometry Let
53. ESC to exit the function of creating volumes Figure 28 Selection of the surfaces of Figure 29 Creation of the volume of the the prism prism 10 Choose the option Render Flat from the mouse menu to visualize a more realistic version of the model Then return to the normal visualization using Render gt Normal B 20 VULCAN TUTORIALS Figure 30 Visualization of the prism with the option Render Flat Ja NOTE In the option Color in the Layers window the user may define the color of the selected layer The color of the layer is that used in the rendering 4 3 Creating the volume of the wheel 1 Deactivate the prism layer gt Visualize the profile layer and activate it doble click on it The volume of the wheel will be created in this layer 2 In the Copy window choose Translation and Surfaces A translation of 10 units will be made To do this enter two points that define a vector for this translation for example 0 0 0 and 0 0 10 3 Choose the option Do Extrude Volume from the Copy window The volume that is defined by the translation will be created 4 Click Select and select the surface of the wheel Press ESC Select the two layers and click them On so that they are visible Choose Render Flat from the mouse menu to visualize a more realistic version of the model Figure 31 VULCAN TUTORIALS B 21 Figure 31 Image of the wheel 5 GENERATING THE MESH Now that the part has been drawn and the
54. LED VOLUME 0 170552E 04 CPU_TIME 0 190087E 03 1 Elapsed Time o Estimated Remaining Time 0 h 3m 10 h Om 0 STEP 79 TIME 0 29523E 00 L2_VELOC 0 763E 01 NUM ITERS FILLED VOLUME 0 170978E 04 CPU_ TIME 0 193691E 03 Elapsed Time Oh 2 9 13 Estimated Remaining Time Oh Om 0 STEP 80 TIME 0 29597E 00 L2_VELOC 0 138E 01 NUM ITERS NORMAL END OF RUN EXECUTION Figure H 33 Output view 49 GET STARTED TUTORIAL LPDC TERMINATE PROCESS If we want to change parameters and calculate again we would click on the last icon This icon will terminate the process In the example we will leave the computer calculating and wait for the end of calculation We will not click on the icon Exiting Vulcan while is still calculating When the pre process is over and we are calculating a process we can exit Vulcan application but without interrupting the calculation Dialog window Are you sure you want to terminate the process part2 started at Tue Apr 24 12 53 13 Figure H 34 Exiting Vulcan while is still calculating Click No and Vulcan will exit We can open Vulcan later during or after the calculation The computer of course must remain on 50 GET STARTED TUTORIAL LPDC Step 9 POST PROCESS Post process means the visualization of the simulation results this is perhaps the most important step of all the casting simulation steps here is where we read and analyze the
55. Lines Since we want to translate 50 units enter two points that define the vector of this translation for example 0 0 0 and 0 0 50 2 Choose Select and select the lines of the octagon Press ESC to conclude the selection Figure 24 Selection of the lines that form the octagon B 18 VULCAN TUTORIALS 3 Since the Z axis is parallel to the user s line of vision the perspective must be changed to visualize the result To do this use the tool Rotate Trackball which is located in the VULCAN Toolbox 6 or on the mouse menu Figure 25 Copying the octagon and changing the perspective 4 Choose Geometry gt Create gt Nurbs surface gt By contour Select the lines that form the displaced octagon and press ESC to conclude the selection Again press ESC to exit the function of creating the surfaces Figure 26 The surface created on the translated octagon 5 In the Copy window choose Translation and Surfaces Make a translation of 110 units Enter two points that define a vector for this translation for example 0 0 0 y 0 O 110 6 To create the volume defined by the translation select Do Extrude Surfaces in the Copy window 7 Click Select and select the surface of the octagon Press ESC The result is shown in Figure 27 VULCAN TUTORIALS B 19 Figure 27 The result of the extrusion 8 Choose Geometry gt Create gt Volume gt By contour Select all the surfaces that form the prism and press ESC 9 Again press
56. New Database x Current HTC Env Figure G 29 HTC Environment label We have pre selected the same options as for the filling analysis Continue to the next label GET STARTED TUTORIAL HPDC G 47 Define operations Foundry comps Strategy Contacts HTC Env Special Output Thermal results Result by C DTime Output frequency s 10 0 Output frequency steps MV Temperature Solidification modulus M Niyama defect Temperature rate IV Solidification time V Porosity M Solid fraction MV Macro porosity Figure G 30 Thermal Special Output label In this label we define the thermal results that we are going to visualize on the post process In the example leave Temperature Solid fraction Solidification modulus and Solidification time Now that we have defined all the problem parameters click on the Close button The parameters will be saved G48 GET STARTED TUTORIAL HPDC Step 7 SAVE PROJECT Before start the calculation don t forget to save the project Click on Save icon J4 NOTE the filename must not contain spaces or symbols Step 8 CALCULATION Project part_hpdc3 Files View Geometry Utilities Data Mesh Workshop Calculate Help SLAE TEENIE TAIR amp SFS 4 eZ FUERA MARIS E a ANE a N Save project Calculate Process info Kill process QUM OSIK al Q rs lt I AA 3 Figure G 31 Calculate Output view and Terminate Proc
57. PDG __ oO oo o y G Now we are ready to import IGES files Let s import a sample file Click the first icon on the process bar and read the following file part_hpdc igs and click Open This file can be downloaded from the VULCAN web page http www quantech es support vulcan aspx the result should look like this Go ET STARTED TUTORIAL HPDC Files iey Jeometry Jniites Oste Mest vorkshop Caculste Help OB BIB AIVSioe0 Banks Oe Ps usicart OSS AIP eK ST SGZAISCIOB8 BIS gt tes F E B Goomery S Zon E Mes c ii Fies y a View iS Utes al K i 2 Y escape Es ents and Setings Jos Antonia sb L cumernios Ouantect exameles Tutorials part_h i H a e A N e 03 2 2007 17 30 19 a2 m x Sa Colapse geometry Time 0 seconds crested 612 p BO Gints 439 lines 0 surfaces 0 volumes ImpornToleran XK Siy on x 7 ka GES File Read jal Geometry read zj Command H Figure G 5 IGES read Close the info window and have a look at the geometry of Figure G 5 by right clicking and doing rotate trackball and zoom in and out Once done with looking at geometry we will start working with different layers one layer for the casting one layer for the mould etc Click on the Layers icon The following window will appear Figure G 6 ___GETSTARTEDTUTORIAL HPDG o o o Gm Double click here to integrate the window
58. See the Tutorials for more details Now click Cancel on this window And click Cancel to continue with the example 34 GET STARTED TUTORIAL LPDC Step 6 OPERATIONS DEFINITION Now we are going to define the specific operations to be simulated Let s click on the Operations icon The following window will appear Figure H 21 Define operations Available operation type Figure H 21 Operations definition 35 GET STARTED TUTORIAL LPDC From the point of view of casting simulation we can divide the casting process into three parts filling solidification and cooling The filling begins when the material starts to enter into the mould and finishes when the molten metal fills the entire mould At this moment solidification starts as metal begins to cool down and solidify solidification finishes when the last part of the casting turns into solid phase At this moment cooling starts and goes all the way down until the casting and mould reaches room temperature In our gravity casting example we are going to run a simulation the filling and solidification parts of the process Click on the add operations icon The following window will appear Name Filling Select operation type Cycling Filling Thermal solidification Thermo Mechanical solidification Mechanical Cancel Here we have to select all the operations we want to simulate one by one Leave Filling and
59. TORIAL GEOMETRY CORRECTION Now we will import this part into Vulcan interface as an IGES file Go to File Import IGES and select the file tutorial_import3 igs This file can be downloaded from the VULCAN web page hittp www quantech es support vulcan aspx Vulcan Project UNNAMED Files View Geometry Utilities Data Mesh Workshop Calculate Help 8 BIVGLVBAlD amp Vlora B O eA RAIAIE TARR KARLES NEL Z A les 8 io A is J S Qe A e U Info window FACS A IGES Global section parameters Sending System CNEXT IGES PRODUCT File name tutorial_import3 igs System ID IBM CATIA IGES CATIA Version 5 Release 1 6 g i H a x 2 1G 7 4 Preprocessor Version CATIA Version 5 Release 16 Product ID pieza_20 Model Scale 1 Unit flag Millimeters Date And Time Exchange 16 4 2007 15 24 20 Minimum Resolution 0 001 Approximate Maximum Coordinate 10000 Author Jos Antonio Organization SNO12345678912 Specification Version 5 Date And Time Modification 16 4 2007 15 24 20 ad al 7 gt S Collapse geometry Time 2 seconds created 796 points 574 lines 0 surfaces 0 volumes ImportTolerance 0 0013 _v y Pick LEFTMOUSE to desplace view ESC to quit if present mouse wheel zooms Pick LEFTMOUSE to desplace view ESC to quit Command Figure D 2 IGES file importing in Vulcan Tg NOTE For more detai
60. VULCAN TUTORIALS VULCAN SIMULATION SOFTWARE FOR CASTING PROCESS OPTIMIZATION Version 10 0 Tutorials VULCAN TUTORIALS Copyright 2007 Quantech ATZ S A Barcelona Spain This tutorial manual may not be reproduced in whole or in part or processed by computer or transmitted in any form or by any other means whether electronic by photocopy by recording or any other method without the prior consent in writing of the owners of the Copyright Quantech ATZ S A Edificio NEXUS Gran Capitan 2 4 08034 Barcelona SPAIN Phone 34 932 047 083 Fax 34 932 047 256 Email info quantech es http www quantech es VULCAN TUTORIALS Foreword This book consists of 8 guided tutorials that will serve as a starting point for using Vulcan The time that will take to complete these tutorials will depend upon the user s skills in the related topics that involve casting processes computer simulation The tutorials are thought to be completed as a self training guide for a Vulcan new user although technical assistance by Quantech ATZ might be necessary The tutorials may require some computer files as a starting point geometries calculations etc which will be provided by Quantech ATZ In order to successfully complete these tutorials we recommend to also having a copy of the Vulcan User s Manual as a reference guide VULCAN TUTORIALS This page is intentionally left blank VULCAN TUTORIALS INDEX Tutorial Su
61. When calculation is finished the user can start the post processing phase this is the results loading view and analysis this is the objective of the finite element simulation This tutorial consists of 9 steps that will guide you trough all the gravity casting simulation process Before we start let s describe Vulcan the interface You can skip the Step O if you have previously worked with the interface J4 NOTE The term Gravity casting simulation includes gravity sand casting gravity die casting and tilt pouring processes GET STARTED TUTORIAL GRAVITY CASTING Step 0 THE PROCESS BAR Vulcan has incorporated an entirely new process bar that will guide us through all the simulations process of filling thermal of our casting process This process bar is normally located on the left side of the screen Bie Pi Ghoti rhe 3 A 3 c R i ry HIGH LOW PRESSURE PRESSURE DIE CASTING DIE CASTING Figure F 1 The process bar ig NOTE If not present you can activate the Process bar from the menu Utilities Tools Toolbars and also change its position to top bottom right etc GET STARTED TUTORIAL GRAVITY CASTING Process bar icons 1 Load results 2 Visualize filling mater result 3 Visualize filling temperature evolution result 4 Visualize filling vectors result 5 Visualize front encounter result 6 Visualize last air result 7 iw Visualize mold erosion
62. X Therman Contacts properties Identifier Comp 1 Comp 2 HTC cond W m 2 K HTC conv W m 2 K Pair1 Part Mould 1000 0 400 0 Figure F 25 Contacts label In the Contacts label Figure F 25 we set the values of the Heat Transfer Coefficients HTC for the contact between the casting and the mould This contact is characterized by two different values HTC conduction and HTC convection Change values to HTC conduction 800 HTC convection 250 And continue to the next label GET STARTED TUTORIAL GRAVITY CASTING iv Define operations Foundry comps Strategy Contacts HTC Envy Special Output HTC environment properties Identifier Foundry component HTC environment A oa Part Env Part HTC Steel Es Mould Env HTC Gray lron Add Modify HTC environment curve TuT Mma HTC environment curve C New Database z x Edit Current HTC Env Figure F 26 HTC Environment label Let s have a look on Figure F 26 Here we set the value of heat transfer coefficient with environment HTC Env in this case environment is the air at the temperature set on the problem definition To continue with the example leave all the default options and continue to the next label J4 NOTE We can modify or create a new value for this parameter by entering on the Edis button and setting a new value The parameter could change for example if the air is not still there is air circulation with fans GET START
63. ace mesh e Check the quality of the mesh generated and make corrections if necessary e Return to geometry view and generate a geometrical volume out of the casting surfaces e Generate a tetrahedral mesh of the casting overwriting the previous mesh e Check again for mesh quality e Return to geometry and generate the mould volume and then generate the final casting and mould mesh overwriting the previous mesh this is the only mesh needed the previous ones were generated for verification Save the project before meshing Go to File Save as Go to the Mesh menu as shown in Figure H 6 les View Geometry Utilities Data Mesh Calculate Help P B kao Sa gt E E RD Unstructured Structured Quadratic elements Element type Mesh criteria Reset mesh data Draw lt Generate mesh Erase mesh Edit mesh Show errors View mesh boundary Create boundary mesh Mesh quality Figure H 6 MAZE BZRMARPGEBDY Mesh generation screen 17 GET STARTED TUTORIAL LPDC The automatic assigned size of the mesh is 12 5 change this value to 6 0 and click OK The result will be like this Figure H 7 Preliminary triangle mesh We can see in Figure H 7 that elements are too big in order to be acceptable Let s decrease the size of the elements to obtain a more uniform mesh J4 NOTE We can change between geometry view and mesh view by clicking on the icon and also change normal view to rende
64. aggregated elements el s Figure D 11 Groove operation before and after deleting it GET STARTED TUTORIAL GEOMETRY CORRECTION Now we will delete a Pocket operation Figure D 12 Pocket operation deletion GET STARTED TUTORIAL GEOMETRY CORRECTION Here wee see EdgeFillet operations gt EdgeFillet 15 EdgeFillet 20 Figure D 13 EdgeFillet operations GET STARTED TUTORIAL GEOMETRY CORRECTION And after the deletion the same parts will look like this Wi chamfer 1 EF Hole 1 A Sketch 4 Sketch 10 Pattern 4 x Figure D 14 Edge fillets deleted GET STARTED TUTORIAL GEOMETRY CORRECTION And finally the deletion of Chamfer operations Figure D 15 Chamfer operation deletion GET STARTED TUTORIAL GEOMETRY CORRECTION Once all operations from Figure D 11 to Figure D 15 are deleted the quality of the mesh generated in Vulcan environment will automatically increase by working in this manner we can decrease the meshing time of our part in Vulcan 3 Now let s see how the part without small radii etc will look in Vulcan Go to Files New Go to Files Import IGES and select the file tutorial_import4 igs This file can be downloaded from the VULCAN web page hitp www quantech es support vulcan aspx After meshing the part we can see the result and compare the effect of removing the fillets machining operations etc Figure D 16 Part
65. ain the temperature evolution and then again temperature in cut Once we have the results like in Figure F 44 go to View results Contour fill Solidification Modulus The result will be SOLIDIF MODULUS 0 0029086 0 0026224 0 0023362 0 00205 0 0017638 0 0014776 0 0011914 0 00090518 0 00061897 0 00033276 step 120_ Contour Fill of SOLIDIF MODULUS Figure F 48 Solidification modulus ___GETSTARTEDTUTORIAL HPDG _ O O OOOO y OG G HPDC HIGH PRESSURE DIE CASTING SIMULATION USING VULCAN Version 10 0 This page is intentionally left blank GET STARTED TUTORIAL HPDC ___GETSTARTEDTUTORIAL HPDG __ _ _ ooo o Z Ga INTRODUCTION In this tutorial we will follow an entire step by step procedure in order to run a high pressure die casting simulation using Finite Element Analysis with Vulcan We will import an IGES geometry into Vulcan s graphical interface mesh it set the process parameters and finally get simulation results temperatures velocities turbulences porosity defects etc Basically a Finite Element Analysis consists of three phases e Pre process e Calculation e Post Process During the pre process phase we will completely define the problem geometry set the types of analyses to perform and establish the physical properties of the materials temperatures etc Once the problem is completely defined we will launch the calculation the total calculation tim
66. alue And now we can see with the higher entities how we have reduced the number of bad lines Ja NOTE One of the operations in the importing process is collapsing the model Figure 3 We say that two entities collapse when being separated by a distance less than the so called Import Tolerance they become one The Import Tolerance value may be modified by going to the Utilities menu opening Preferences and bringing up the Import card By default the Automatic import tolerance value is selected With this option selected VULCAN computes an appropriate value for the Import Tolerance based on the size of the geometry Collapsing the model may also be done manually This option is found in Utilities gt Collapse gt Model VULCAN TUTORIALS 2 Correcting ERRORS IN THE IMPORTED GEOMETRY The great diversity of versions formats and software frequently results in differences errors between the original and the imported geometry With VULCAN these differences might result into imperfect meshes or prevent meshing altogether In this section we will see how to detect errors in imported geometry and how to correct them 2 1 Correcting the geometry 1 If we select the higher entities command we will see how there are different places with different kinds of errors in this part If not select delete lines and delete all the lost lines of the part selecting all the part you only will delete the lost lines not the lines that belongs to a surfac
67. and line we have to press Esc to accept the selection and leave The following message will appear in the command line Assigned size 30 to 8 new entities e click Close to close the enter value window Now we repeat points a to e for lines surfaces and volumes with the same size of 30 oF ri Also we can use the button gt to assign directly the size to the points lines and surfaces Once the sizes are all assigned we generate the mesh again same general mesh size 5 The result shall look like this Figure G 19 Gee ET STARTED TUTORIAL HPDC Dialog window W Mesh generated Num of Tetrahedra elements 84809 Num of nodes 14831 Figure G 19 Generated mesh Now that the mesh is generated we will see in detail how to set the process parameters for this particular type of problem high pressure die casting We will continue the step by step process with the Process bar ___GETSTARTEDTUTORIAL HPDC O Oooo y y YOGa Step 4 FOUNDRY PROCESS DEFINTION Until now we were dealing with geometrical parameters definitions etc From now on we will deal with real foundry parameters characteristics processes etc It is very important to set the parameters properly To have closer parameters to reality give us more accurate results So read on and let s do casting simulation The first step we take once we have the casting and mould geometry defined and meshed is let Vulcan know what type of p
68. as been created to this point the image can be centered on the screen by choosing in the Mouse Menu Zoom Frame This option is also available in the toolbar Finish the square by creating point 10 10 0 and the lines that join this point with points 2 and 3 Now we will create the surface that these four lines define To do this access the create surface command by choosing Geometry gt Create gt NURBS surface gt By contour This option is also available in the toolbar Vulcan then asks the user to define the 4 lines that describe the contour of the surface Select the lines using the cursor on the screen either by choosing them one by one or selecting them all with a window Next press Escape As can be seen below the new surface is created and appears as a smaller magenta colored Square drawn inside the original four lines VULCAN TUTORIALS A 9 Once the surface has been created the mesh can be created in the same way as was done for the line From the Top Menu select Mesh gt Generate mesh An Auxiliary Window appears which asks for the maximum size of the element in this example we define a size of 1 When the mesh it s finished if we want to see the mesh we have to select this option This option allows to show or to hide the mesh We can see that the lines containing elements of two nodes have not been meshed Rather the mesh generated over the surface consists of planes of three
69. ates are 40 0 On dividing the line a new point entity has been created Notice that the pointer has become across Select the line that is to be divided by clicking on it Press ESC to indicate that the process of dividing the line is finished Figure 3 Division of the straight line near point coordinates 40 0 2 3 Creating a 3 8 radius circle around point 40 0 Choose the option Geometry Create Object Circle The center of the circle 40 0 is a point that already exists To select it go to Contextual Join C a on the mouse menu right button The pointer will become a cross which means that you may click on the point Enter any point that together with the center of the circle defines a normal to the XY plane i e 0 0 40 Enter the radius of the circle The radius is 3 8 Two circumferences are created the inner circumference represents the surface of the circle Press ESC to indicate that the process of creating the circle is finished AO dho eee Figure 4 Creating a circle around a point 40 0 In VULCAN the decimals are entered with a point not a comma VULCAN TUTORIALS 2 4 Rotating the circle 3 degrees around a point 1 Use the Move window which is located in Utilities Move Entities type E uifaces g 2 Within the Move menu and from among the Transformation Transtormation Rotation r possibilities select Rotation The Angle 3 Degrees type of entity to receive the ro
70. ation thermo mechanical solidification Lets load the filling operation and analyze the results Go to Vulcan results Load results And select the Filling1 operation Load results Load from Select Operation File Select operation Operations Filling Z Load file File Cancel Figure G 37 Results loading Click Ok and the filling results will be loaded Ja NOTE Every time we toggle when we return to post process we have to load the results G54 GET STARTED TUTORIAL HPDC Now that we have all the filling results loaded let s begin for example to see the evolution of the casting material in the mould where there could be air entrapment or the advancing fronts of material could encounter the last spots of the mould to be filled etc To see this we will use a tool called filling mater In this animation we will see the material free surface in red the filled areas in grey and the mould will be transparent Go to main menu Vulcan results Filling mater or select the button 3 Once the Animate window appears press the Play button M Results View F Automatic Limits analysis animation I Deformation profile Ir Endless J From step 1 to step Bg Set duration by TotalTime 5 s l use step values as scaler C Delay between steps Bo ms C Use step values as seconds Step number 47 Step value 0 026 00 0 T Create a stereoscopic an
71. ay between steps 52 ms C Use step values as seconds Step number 54 Step value D 020co0 0C 54 i 009090 M Save TIFF Save MPEG F Create a stereoscopic animation Default v Resize Close Figure F 39 Filling mater animation In Figure F 39 we can see the Animate window and the control buttons We can keep this window open while we rotate zoom in and zoom out the casting Let s explain the basic Animate controls GET STARTED TUTORIAL GRAVITY CASTING Basic Animate window controls Automatic Limits GiD searches for the minimum and maximum values of the results along all the steps of the analysis and uses them to draw the results view through all the steps Previously it needs to visualize some resultls Deformation Permits to record animation with a specific deformation Endless The animation continues indefinately Total time specfies the duration of the clip Delay Specify a delay time between steps in milliseconds Use step values as seconds the number of step will be used to the duration of the clip From step to step K allows the user to do an animation between step number and setp number J both included This is also useful to skip the first step of an animation of a deformed mesh with a result visualization which is the original state of the mesh without deformation and without the result visualization Save TIFF JPEG GIFs on Save snapshots in TIFF JPEG or GIF format of each s
72. ayer Cast e Close the layers window The resulting geometry at this moment shall look like Figure G 8 Figure G 8 High pressure die casting geometry G4 STARTED TUTORIAL HPDC The geometrical entities in Vulcan have the following hierarchy order Points gt Lines gt Surfaces gt Volumes We can interpret the hierarchy by higher entities and lower entities For example a surface is higher than a line a surface is lower than a volume etc we cannot delete a surface if there are related higher entities present Volumes In Figure G 8 we can see the points in black lines in blue and surfaces in pink There are always points that define line ends lines that define surfaces etc Now that we have a geometry to work with let s begin with the next step geometry treatment ___GETSTARTEDTUTORIAL HPDG Z oZ o o o OGA Step 2 GEOMETRY TREATMENT This geometry apparently has no errors so we won t collapse points or lines Let s check the integrity c of the geometry by o Draw higher option Files View Geometry Utilities Data Mesh Wo OB 21GB F Vlas Onee Fle XY re MAE HigherEntities 3 Other 2 Interior Figure G 9 Draw Higher screen G6 ET STARTED TUTORIAL HPDC In Figure G we can check the geometrical integrity of the model before we mesh it To form a closed surface all the lines need to be the end of two surfaces Interior in the figure If there would be open edges on the geometr
73. bject A Initiation basic tools for geometry B Tutorial Implementing a mechanical part C Tutorial Implementing a cooling pipe D Geometry preparation in other CAD systems E Geometry correction tools for correcting geometries once imported into Vulcan environment Tutorial of a complete casting process Gravity casting Th G Tutorial of a complete casting process High Pressure die casting Tutorial of a complete casting process Low Pressure die casting Tg NOTE For beginning level users we recommend to complete the tutorials in the given order VULCAN TUTORIALS This page is intentionally left blank VULCANTUTORIALS A A INITIATION TO VULCAN With this example the user is introduced to the basic tools for the creation of geometric entities and mesh generation A 2 This page is intentionally left blank VULCAN TUTORIALS VULCAN TUTORIALS A 3 FIRST STEPS Before presenting all the possibilities that Vulcan offers we will present a simple example that will introduce and familiarize the user with the Vulcan program The example will develop a finite element problem in one of its principal phases the preprocess and will include the consequent data and parameter description of the problem This example introduces creation manipulation and meshing of the geometrical entities used in Vulcan First we will create a line Next we will save the project and it will be described in the Vulcan data base form
74. ble foundry components Selected foundry components Mould Part Figure H 26 Thermal settings In this screen foundry components are already selected Go to the next screen 42 GET STARTED TUTORIAL LPDC Define operations Foundry comps Strategy Contacts HTC Env Special Output General parameters Perform de molding De molding only casting De molding all foundry components De molding termination C Casting temperature Temperature value C 500 0 Termination by C Time Time value s Casting temperature Temperature value C De molding by Time Time value s 120 0 l Figure H 27 Thermal Strategy label In this screen we define the De moulding and Termination characteristics of our process In the current problem we leave de moulding deselected and we select termination by Casting temperature 300 C Click on the next label 43 GET STARTED TUTORIAL LPDC Define operations Foundry comps Strategy Contacts HTC Env Special Output Contacts properties Identifier Comp 1 Comp 2 HTC cond W m 2 K HTC conv W m 2 K Pair Part Mould 2700 0 1000 0 Figure H 28 Thermal Contacts label Here again we set the HTC conduction to 2000 and HTC convection to 1000 and continue to the next label 44 GET STARTED TUTORIAL LPDC Define operations Foundry comps Strategy C
75. click OK 3 Once the mesh generating process is finished select the icon to visualize the result Figure 49 Figure 499 A detail of the mesh generated by default The Chordal Error is the distance between the element generated by the meshing process and the real profile B 34 VULCAN TUTORIALS 7 2 Generating a mesh using Chordal Error oe o oe Choose Mesh Unstructured Sizes by Chordal error Now the maximum element size must be entered Enter 15 on that command line The next step is entering the chordal error Enter 0 05 Choose Mesh Generate Mesh A greatly improved approximation has been achieved in zones containing curves and more specifically along the wheel profile and the profile of the hole See Figure 50 Figure 50 A detail of the mesh generated using Chordal Error VULCAN TUTORIALS C 1 CASE STUDY 2 C IMPLEMENTING A COOLING PIPE This case study shows the modeling of a more complex piece and concludes with a detailed explanation of the corresponding meshing process The piece is a cooling pipe composed of two sections forming a 60 degree angle The modeling process consists of four steps e Modeling the main pipes e Modeling the elbow between the two main pipes using a different file e Importing the elbow to the main file e Generating the mesh for the resulting piece At the end of this case study the user should be able to use the CAD tools available in VULCAN as well as the optio
76. d and we select termination by Casting temperature 300 C Click on the next label GET STARTED TUTORIAL GRAVITY CASTING Define operations Foundry comps Strategy Contacts HTC Env Special Output Contacts properties E Ee E Identifier Comp 1 Comp 2 HTC cond W m 2 K HTC conv W m 2 K 13 Pair1 Part Mould 1000 0 400 0 Figure F 30 Thermal Contacts label Here again we change the HTC conduction to 800 and HTC convection to 250 and continue to the next label GET STARTED TUTORIAL GRAVITY CASTING Foundry comps Strategy Contacts HTC Env Special Output HTC environment properties Part Env HTC Steel Mould Eny HTC Gray lron Add Modify HTC environment curve AT Mm a m HTC environment curve C New Database z x Edit Current HTC Eny Figure F 31 HTC Environment label We have pre selected the same options as for the filling analysis Continue to the next label GET STARTED TUTORIAL GRAVITY CASTING Define operations NY Fillings Foundry comps Strategy Contacts HTC Env Special Output Thermal results Result by C DTime Output frequency s Output frequency steps M Temperature Solidification modulus M Niyama defect Temperature rate Solidification time M Porosity M Solid fraction M Macro porosity Figure F 32 Thermal Special Output label In this label we define the thermal results that
77. d by choosing Geometry gt View geometry VULCAN TUTORIALS A 11 In order to create a volume from the existing geometry firstly we must create a point that will define the height of the cube This will be point 5 with coordinates 0 0 10 superimposed on point 1 To view the new point we must rotate the figure by selecting from the Mouse Menu Rotate gt Trackball This option is also available in the toolbar Rotate the figure until the following position is achieved Next we will create the upper face of the cube by copying from point 1 to point 5 the surface created previously To do this select the copy command Utilities gt Copy In the Copy window we define the translation vector with the first and second points in this case 0 0 0 and 0 0 10 Option Do extrude surfaces must be selected this option allows us to create the lateral surfaces of the cube A 12 VULCAN TUTORIALS Entities type Surfaces z Transformation Translation 7 First point Num x 0 0 y 0 0 z 00 Second point Num x 0 0 y 0 0 e 2 10 Duplicate entities Do extrude Surfaces z l Create contacts V Maintain layers Multiple copies 1 Select Cancel Ja NOTE If we look at the Copy Window we can see an option called Duplicate entities By activating this option when the entities are copied in this case from point 1 to point 5 Vulcan would create a new point point 6 with the same coordinates as point 5 If the
78. e HigherEntities 2 Interior 1 Boundary VULCAN TUTORIALS 2 First of all we go to close the holes of the part 5 holes Go to Geomtry gt Create gt Hole Nurbs Surface gt By Contour and select the lines that border on the surface Figure 87 Creation of surfaces 3 Also we have to close and repair this bad surfaces in one corner of the part First of all we have to generate the missing surfaces then with the option join ci we merge the bad surfaces and finally we collapse all the points of this area Figure 88 Correction of the corner VULCAN TUTORIALS 4 Now we have the surface almost ready to generate the volume but first we have to correct these previous issues We can solve these kinds of problems collapsing the lines with higher entities 1 But for do this we have to increase the tolerance value Preferences General Graphical Meshing Exchange Fonts Format Grid Import V Automatic collapse after import Automatic import tolerance value Import tolerance 0 5 Collapse Ignoring layers Each layer separately I IGES Curve on surface from 3D I7 IGES Create all in layer to use Export IV IGES B Rep output style HigherEntities 2 Interior 1 Boundary Accept Reset Close Figure 89 Changing the collapsing tolerance value 5 We have to be careful to collapse with this value and only choose the lines that w
79. e want to collapse because we can break the part 6 And we have the part closed ready to create the volume and mesh VULCAN TUTORIALS HigherEntities 2 Interior Figure 90 Final part GET STARTED TUTORIAL GRAVITY CASTING F GRAVITY GRAVITY CASTING SIMULATION USING VULCAN Version 10 0 GET STARTED TUTORIAL GRAVITY CASTING This page is intentionally left blank GET STARTED TUTORIAL GRAVITY CASTING INTRODUCTION In this tutorial we will follow an entire step by step procedure in order to run a gravity casting simulation using Finite Element Analysis with Vulcan We will import an IGES geometry into Vulcan s graphical interface mesh it set the process parameters and finally get simulation results temperatures velocities turbulences porosity defects etc Basically a Finite Element Analysis consists of three phases e Pre process e Calculation e Post Process During the pre process phase we will completely define the problem geometry set the types of analyses to perform and establish the physical properties of the materials temperatures etc Once the problem is completely defined we will launch the calculation the total calculation time will depend on the complexity of the problem this is the number of elements in both the casting and the mould During the calculation time user s participation is not required The calculation will let us know when is finished
80. e Add new foundry component icon 7 The following window will appear Add a new foundry component Ea Mame Moulde select a foundry component type i Part Mould O Filling system Chill Filter Feeding system Core Cooling system Sleeve Ok Cancel ___GETSTARTEDTUTORIAL HPDG 8H This window has to be used in case of need to insert more components to the tree such as more parts of the mould or cores On the example shown there are only two layers the whole mould and the part so there is no need to create a new foundry component In Figure G 19 we can also see the Use coating checkbox If we use this option we can change the conductivity and the thickness for the specific coating we are using Now click on the Edit button this window will open Material properties Material name AISi Mg Fluid Thermal Phase Change Mechanical Composition Temperature independent data Latent heat J Kg 4 30518E 5 Solidus temperature C 542 0 Liquidus temperature C 613 0 Temperature dependent data Material properties Solid fraction Table Graph Table Graph Points Temp C Temperature vs Solid fraction 542 562 561 0 0 0 0 0 0 0 0 1 2 3 4 5 6 8 0 542 553 8 565 7 577 5 589 3 601 2 613 VOX Addto database Cancel Figure G 20 Editing material properties Here we can see the material properties in both table and graphical views We can change
81. e corresponding submenu for line creation has the following options Contextual dotate D D IN gu Image to clipboard s Quit Base Join Ctrl a Point In Line Point In Surface Tangent In Line Normal In Surface Arc Center Options Undo Close Number Escape A 6 VULCAN TUTORIALS Once the line has been generated the project should be saved To save the example select from the Top Menu Files gt Save The program automatically saves the file if it already has a name If it is the first time the file has been saved the user is asked to assign a name For this an Auxiliary Window will appear which permits the user to browse the computer disk drive and select the location in which to save the file Once the desired directory has been selected the name for the actual project can be entered in the space titled File Name Save Project Directory Sy TutorialE xamples fe c V Preview Wf optimizacion gid W ToMesh4 gid W tutorialcasting2 gid No Preview J File name initiation Save Files of type Yulcan project gid v Cancel Ja NOTE Next the manner in which Vulcan saves the information of a project will be explained Vulcan creates a directory with a name chosen by the user and whose file extension is gid Vulcan creates a set of files in this directory where all the information generated in the present example is saved All the files have the same name of th
82. e directory to which they belong but with different extensions These files should have the name that Vulcan designates and should not be changed manually Each time the user selects option save the database will be rewritten with the new information or changes made to the project always maintaining the same name To exit Vulcan simply choose Files gt Quit To access the example example gid simply open Vulcan and select from the Top Menu Files gt Open An Auxiliary Window will appear which allows the user to access and open the directory iniciacion gid VULCAN TUTORIALS A 7 2 CREATION AND MESHING OF A SURFACE We will now continue with the creation and meshing of a surface First we will create a second line between points 1 and 3 3 0 10 0 1 0 0 0 2 10 0 0 We will now generate the second line We will now use again the Coordinates Window to enter the points Utilities gt Tools gt Coordinates Window Select the line creation tool in the toolbar select the point 0 O 0 with the option Join Ctrl a and enter point 0 10 0 in the Coordinates Window and click Apply Q Coordinates window C System Cartesian x Local axes Global x 0 00000 y 10 z 0 00000 Create new point Ask Change Use tab Shift tab and Return Apply Close A 8 VULCAN TUTORIALS 3 0 10 0 1 0 0 0 2 10 0 0 With this a right angle of the square has been defined If the user wants to view everything that h
83. e hole Figure 21 and press ESC CA Figure 20 The selected surface in Figure 21 The selected lines that which to create the hole define the hole 4 Again press ESC to exit this function B 16 VULCAN TUTORIALS oe Figure 22 The model part with the hole in it 4 CREATING VOLUMES FROM SURFACES The mechanical part to be constructed is composed of two volumes the volume of the wheel defined by the profile and the volume of the axle which is a prism with an octagonal base that fits into the hole in the wheel Creating this prism will be the first step of this stage It willl be created in a new layer that we will name prism 4 1 Creating the prism layer and translating the octagon to this layer 1 Inthe Layers window create a new layer and rename as a prism 2 Select the prism layer and doubleclick to configure it as the activated layer 3 With the right button mouse over the layer prism choose send to Lines Select the lines that define the octagon Press ESC to conclude the selection VULCAN TUTORIALS B 17 Figure 23 The lines that form the octagon And doubleclick 4 Select the profile layer and click Off to deactivate it gt again over the layer prism 4 2 Creating the volume of the prism 1 First copy the octagon at a distance of 50 units relative to the surface of the wheel which is where the base of the prism will be located In the Copy window choose Translation and
84. e other layer called the aux layer When the design of the part has been completed the entities in the aux layer will be eliminated Ja NOTE You can find the finished model in the VULCAN CD ROM B 4 VULCAN TUTORIALS 1 2 Creating two new layers 1 Open the layer management window This is found in Utilities Layers 2 Create two new layers called aux and profile Select layerO and with the right button mouse select Rename and write the new name aux Then create a new layer called profile using the option New layer of the right button mouse and rename it as a profile 3 Choose aux as the activated layer To do this doubleclick on aux to highlight it From now on all the entities created will belong to this layer Layers Layers jaxso7 Jarene C WO FU Tr 2 profile Figure 1 The Layers window Figure 2 The Layers window VULCAN TUTORIALS B 5 2 CREATING A PROFILE In our case the profile consists of various teeth Begin by drawing one of these teeth which will be copied later to obtain the entire profile 2 1 Creating a size 55 auxiliary line 1 Choose the option Line by going to Geometry gt Create Straight Line or by going to the VULCAN Toolbox 2 Enter the coordinates of the beginning and end points of the auxiliary line For our example the coordinates are 0 0 and 55 0 respectively Besides creating a Straight line this operation implies creating the end points of t
85. e process bar will open automatically it will be used and described in detail in the present tutorial Now that we have the Vulcan pre process interface opened and set lets begin with the first step GET STARTED TUTORIAL LPDC Step 1 READ AN IGES FILE Before reading the IGES file we are going to set Vulcan parameters in the optimal configuration for importing this type of files In the main menu click on Utilities Preferences The following window will open Preferences General Graphical Meshing Exchange Fonts Format Grid Import V Automatic collapse after import V Automatic import tolerance value Collapse Ignoring layers Each layer separately V IGES Curve on surface from 3D IGES Create all in layer to use Export V IGES B Rep output style Reset Close Figure H 4 Setting importing preferences The following checkboxes must be selected in Figure H 4 M Automatic collapse after import M Automatic import tolerance value Accept the changes and Close the window GET STARTED TUTORIAL LPDC Now we are ready to import IGES files Let s import a sample file Click the first icon on the process bar and read the following file piezalpdc igs and click Open This file can be downloaded from the VULCAN web page hitp www quantech es support vulcan aspx Select it and click Open the result should look like this GET STARTED TUTORIAL LPD
86. e will depend on the complexity of the problem this is the number of elements in both the casting and the mould During the calculation time user s participation is not required The calculation will let us know when is finished When calculation is finished the user can start the post processing phase this is the results loading view and analysis this is the objective of the finite element simulation This tutorial consists of 9 steps that will guide you trough all the HPDC casting simulation process Before we start let s describe Vulcan interface You can skip Step O if you have previously worked with this interface Tg NOTE The term high pressure die casting includes both hot chamber process and cold chamber process in the diecasting nomenclature but not the process called low pressure die casting which is treated separately in the next tutorial GA ET STARTED TUTORIAL HPDC Step 0 THE PROCESS BAR Vulcan has a process bar that will guide us trough all the preparations settings and calculation of our casting process This process bar is normally located on the left side of the screen Files View Geometry Utilities Data Mesh Workshop Calculate Help SA AUEN E E LEk A FFERR MAE E PEEN ein E IES Figure G 1 The Process bar highlighted in red ig NOTE If not present you can activate the Process bar from the menu Utilities Tools Toolbars and also change its position to
87. en GET STARTED TUTORIAL HPDC Define operations Foundry comps Strategy Contacts HTC Env Special Output General parameters l Perform de molding De molding only casting De molding all foundry components De molding termination De moalding by Time Time value s 120 0 Casting temperature Temperature value C 500 0 Termination by C Time Time value s Casting temperature Temperature value C Figure G 27 Thermal Strategy label In this screen we define the De moulding and Termination characteristics of our process In the current problem we leave de moulding deselected and we select termination by Casting temperature 300 C Click on the next label GET STARTED TUTORIAL HPDC Define operations Foundry comps Strategy Contacts HTC Env Special Output Contacts properties Identifier Comp 1 Comp 2 HTC cond W m 2 K HTC conv W m 2 Pairl Part Mould 7000 0 3000 0 Figure G 28 Thermal Contacts label Here again we leave the HTC conduction in 2000 and HTC convection in 1000 and continue to the next label Gee ET STARTED TUTORIAL HPDC Define operations Foundry comps Strategy Contacts HTC Env Special Output HTC environment properties zar Identifier Foundry component HTC environment 73 PartEnv Part HTC Aluminium Mould Env Mould HTC Graylron Add Modify HTC environment curve Component HTC environment curve C
88. er 10 on the command line VULCAN asks for the chordal error Enter 0 1 Choose Mesh gt Generate Mesh A window comes up in which to enter the maximum element size of the mesh to be generated Assign 8 and click OK 7 When the meshing process is finished a window appears with information on the mesh that has been generated Click OK to visualize the mesh 8 Choose Mesh gt View Mesh Boundary to see only the contour of the volumes meshed but not their interior 9 This way the visualization may be rendered using the various options on the Render menu located on the mouse menu Or U AA O Tg NOTE By default VULCAN corrects element size depending on the form of the entity to mesh This correction option may be deactivated or reactivated in the Preferences window on the Meshing card under the name Automatic correct sizes VULCAN TUTORIALS N we PARP aes AAAI er rata Was a 8 LAA Figure 33 The mesh generated for the pie GET STARTED TUTORIAL GEOMETRY CORRECTION D GEOMETRY PREPARATION IMPORTING CAD GEOMETRIES INTO VULCAN ENVIRONMENT Version 10 0 GET STARTED TUTORIAL GEOMETRY CORRECTION This page is intentionally left blank GET STARTED TUTORIAL GEOMETRY CORRECTION INTRODUCTION In Finite Element Analysis the meshing is a very important step towards the success of the simulation process Finite element meshes are very precise and they fit very well to the real shape of the casting
89. erature 25 0 ig Model units Meter Centimeter Millimeter Gravity direction Problem dimension C 2D Figure F 16 The Process type General window GET STARTED TUTORIAL GRAVITY CASTING In the Symmetries label Figure F 17 we have to define the symmetry planes created if there are no planes of symmetry simply leave No planes selected U Define the problem Process type General Symmetries Number of planes Mo planes 7 Plane 2 Plane Plane 1 Plane 2 Figure F 172 The Process type Symmetries window Now the gravity casting process is defined click Close to continue to the next step J4 NOTE All the changes made will be saved upon clicking on the Close button GET STARTED TUTORIAL GRAVITY CASTING Step 5 FOUNDRY COMPONENTS DEFINTION Click on the Components definition icon The following window will open Figure F 18 U Define foundry components Layers Available m Assigned cast mould Parameters m Material properties Material group m Material C New D atabase Oe Edit Temperature Coating Initial temperature C f 500 0 Calculate ingate area ET U e coating Conduction Cal m C 0 8 Thickness mm i 00 0E 6 Figure F 18 Foundry components definition GET STARTED TUTORIAL GRAVITY CASTING First we have to assign each layer to the correspondin
90. erial AlSi Mg Temperature Coating Initial temperature C Calculate ingate area M Use coating Conduction Cal m C 0 6 Thickness mm 100 0E 6 Figure G 18 Foundry components definition ___GETSTARTEDTUTORIAL HPDC 8 Now perform the same procedure for the mould first selecting the Mould component on the tree and then mould from Available window Again it should move to Assigned window Assign in the Mould materials group the Steel material at initial temperature of 300 Degrees Celsius Define foundry components Layers Available Assigned mold Parameters Material properties Material group Permanent Mould Z Material C New Database Steel X40CrMoV5 m z Edit Current material Steel X40CrMoV5 m Temperature Coating Initial temperature C M Use coating Conduction Cal m C 0 8 Thickness mm 100 0E 6 Figure G 19 Foundry components definition Click Close to save the changes G34 GET STARTED TUTORIAL HPDC Tg NOTE Let s explain some of the icons that appear in the Components definition window You can skip this note to continue with the example and go to the Step 6 Click again on the icon In case of having multiple layers you can assign and unassign layers to foundry components by using the gt icons for example in case of having the mould divided in upper part and lower part on different layers or in case of having to make changes Now click on th
91. ess icons GET STARTED TUTORIAL HPDC G 49 Now following the column of icons shown in Figure G 31 we first saved the project and then Calculate it The calculation time will depend upon the complexity of the problem The calculation window will look like this Calculate the simulation Calculate General options Solver accuracy Low D High Select operation Calculated operations Name From operation Filling m To operation Figure G 32 Calculation window Select From operation filling To operation Thermal1 and click OK The calculation will start Process window Project Starttime UID Priority borrar Mon Apr 23 12 47 06 6888 Normal Outputview Terminate Remote Close Figure G 33 Calculation window G 50 GET STARTED TUTORIAL HPDC We can view the Output view by clicking the icon and see the calculation status and also interrupt and cancel the calculation by Terminate the process make changes and Calculate again Close the window OUTPUT VIEW Once the window is closed we can still access to the output view by clicking on the icon And we will see the calculation process output info for borrar Mon Apr 23 12 47 06 z CPU TIME 0 731177E 02 Elapsed Time Oh im 13 Estimated Remaining Time 0h 18 m 20 STEP 22 TIME 0 29455E 02 L2_VELOC 0 297E 01 NUM ITERS FILLED VOLUME 0 364880E 04 CPU_TIME 0 767369E 02 Elapsed Time Estimated
92. f VELOCITIES VELOCITIES size 15 Figure G 39 Filling vectors animation The colour scale represents the module of velocity In Figure G 39 we can see the highest velocities in red and the lowest velocities in blue ___GETSTARTEDTUTORIAL HPDC O O ooo y y OG Now we want to see parameters like temperature of front encounters early cooling during filling and possible solidification during filling To see this kind of results we will go to Vulcan results Temperature evolution or select the button e TEMPERATURES 850 849 47 848 93 646 4 647 86 647 33 646 6 846 26 845 73 645 2 step 0 0253105 Contour Fill of TEMPERATURES Figure G 40 Temperature evolution during filling Here we can see the temperatures and the temperatures colour scale and also the time step since the start of filling G 58 GET STARTED TUTORIAL HPDC Now we will load the second foundry operation we had run solidification Solidification goes from the end of filling until the casting is completely solid Let s see the results Go to Vulcan results Load results and load the Thermal operation Load results Load from Select Operation O File Select operation Operations Thermal A Load file Cancel Figure G 41 Thermal operation loading Once the results are loaded click Ok and let s see some solidification results This time we will see temperature evolution in both casting and mould excess
93. g foundry component On the example shown the Part component is highlighted on the tree In the Available window select cast and click on the Icon The cast layer will move to the Assigned window Now select the Material group and specific material from the database and set a temperature of 1500 Degrees Celsius as shown in Figure F 19 Define foundry components Layers Available Assigned mould cast 4 gt Parameters Material properties Material group Steel Material New Database 40CrMoV5 z wg x lt Edit Current material X40CrMo 5 Temperature Coating Initial temperature C 11500 Calculate ingate area Use coating Conduction Cal m C 0 8 Thickness mm 100 0E 6 Close Figure F 19 Foundry components definition GET STARTED TUTORIAL GRAVITY CASTING Now perform the same procedure for the mould first selecting the Mould component on the tree and then mould from Available window Again it should move to Assigned window Assign in the Mould materials group permanent or sand mould the sand material at initial temperature of 20 Degrees Celsius Define foundry components Layers Available Assigned mould Parameters Material properties Material group Sand Mould Material C New Database Sand MA Edit Current material Sand Temperature Coating Initial temperature C M Use coating Conduction Cal m C Thickness mm 10
94. geometrical parameters definitions etc From now on we will deal with real foundry parameters characteristics processes etc It is very important to set the parameters properly The closer the parameters to reality the more accurate results So read on and let s do casting simulation The first step we take once we have the casting and mould geometry defined and meshed is let Vulcan know what type of process we are going to calculate Click on define the main process characteristic the 4 icon A window with 3 labels will appear In the Process type label select Low pressure as shown in Figure H 14 26 GET STARTED TUTORIAL LPDC Define the problem Process type General Symmetries Select process type T High pressure Lost Foam Figure H 14 The Process type window Once this step is taken Vulcan adjusts all the internal parameters and the remaining icons to this particular type of process 2 GET STARTED TUTORIAL LPDC In the General label we have a set options to define units gravity direction with respect to the coordinate system compass environment temperature etc Set the gravity direction to Z and the Environment temperature to 25 Degrees Celsius as shown in Figure H 15 Define the problem Process type Symmetries Gravity constant 9 81 m s2 Environment temperature 25 0 C Model units O Centimeter Millimeter Gravity directi
95. he Material group and specific material from the database and set a temperature of 640 Degrees Celsius as shown in Figure H 18 Define foundry components Layers Available Assigned mould cast Parameters Material properties Material group Aluminium Z Material C New Database AISi7Mg X Edit Current material AISI Mg Temperature Coating Initial temperature C M Use coating Conduction Cal m C 0 8 Thickness mm 100 0E 6 Figure H 18 Foundry components definition 31 GET STARTED TUTORIAL LPDC Now perform the same procedure for the mould first selecting the Mould component on the tree and then mould from Available window Again it should move to Assigned window Assign in the Mould materials group the steel material at initial temperature of 20 Degrees Celsius Define foundry components Layers Available Assigned mould Mould Parameters Material properties Material group Permanent Mould Z Material C New Database Steel x40CrMo5 m Edit Current material Steel x40CrMow 5 m Temperature Coating Initial temperature C Use coating y Conduction Cal m C 0 6 Thickness mrm 100 0E 6 Figure H 19 Foundry components definition Click Close to save the changes 32 GET STARTED TUTORIAL LPDC Tg NOTE Let s explain some of the icons that appear in the Components definition window You can skip this note to continue with the example
96. he filling stalk and also the Time vs Pressure curve of the filling machine Define operations PSS Sa STFilling i Thermal Foundry comps Strategy Contacts HTC Env Special Output General parameters Mould surface finish Roughness Low specular a 4 3 Distance from free surface mm 150 0 Flow defined by Pressure curve Filling time Pressure curve Table Graph Points Time msec Pressure mbar 1 100 0 100 0 2 5000 0 250 0 3 10000 0 300 0 Time vs Pressure 200 166 7 133 3 100 100 1750 3400 5050 6700 8350 1e 04 VOX Without mould M Run without mould Figure H 29 Strategy label D Select the option Filling time in Figure H 29 enter a value of 0 3 sec and continue to the next label 38 GET STARTED TUTORIAL LPDC Define operations Nam Foundry comps Strategy Contacts HTC Env Special Output AYN Therman Contacts properties Identifier Comp 1 Comp 2 HTC cond W m 2 K HTC conv W m 2 K Pair Part Mould 2700 0 1000 0 Figure H 23 Contacts label In the Contacts label Figure H 23 we set the values of the Heat Transfer Coefficients HTC for the contact between the casting and the mould This contact is characterized by two different values HTC conduction and HTC convection Keep values to HTC conduction 2000 HTC convection 1000 And continue to the next label 39 GET STARTED TUTORIAL LPDC Define operations NY Gri
97. he foreground of Figure 30 Press ESC See Figure 28 Figure 28 Creating a NURBS Surface to close the outlet in the foreground C2000 VULCAN TUTORIALS 3 Choose Geometry gt Edit gt Hole NURBS surface Select the NURBS surface just created Then select the lines defining the hole Press ESC The result is shown in Figure 31 4 Repeat the process for the other outlet to be closed 5 From the Files menu select Save in order to save the file Enter a name for the file and click Save Figure 296 A rendering of the T junction VULCAN TUTORIALS C 21 5 IMPORTING THE T JUNCTION TO THE MAIN FILE The two parts of the model have been drawn Now they must be joined so that the final volume may be generated and the mesh generation may be carried out 5 1 Importing a VULCAN file STEP 13 1 Choose Open from the Files menu Select the file that where the first part created in section 3 was saved Click Open 2 Select the ok layer as a Layer To use so that the imported file will be in this layer 3 Choose Files gt Import gt Insert VULCAN geometry from the Files menu Select the file where the second part created in section 4 was saved Click Open 4 The T junction appears Keep in mind that the lines defining the end of the first pipe background of the T junction and which have been imported were already present in the first file Notice that the lines overlap This overlapping will be remedied by collapsing the lines
98. he line 3 Press ESC to indicate that the process of creating the line is finished 4 lf the entire line does not appear on the screen use the option Zoom Frame which is located either in the VULCAN Toolbox or in Zoom on the mouse menu Figure 2 Creating a straight line Ja NOTE The option Undo located in Utilities gt Undo enables the user to undo the most recent operations When this option is activated a window appears in which to select all the operations to be undone The VULCAN Toolbox is a window containing the icons for the most frequently executed operations For information on a particular tool click on the corresponding icon with the right mouse button The coordinates of a point may be entered on the command line with either a separation between them or a comma between them If the Z coordinate 0 Ois not entered it is considered 0 by default After entering the numbers press Return Another option for entering a point is using the Coordinates Window found in Utilities gt Tools gt Coordinates Window Pressing the ESC key is equivalent to pressing the center mouse button B 6 VULCAN TUTORIALS 2 2 Dividing the auxiliary line near point coordinates 40 0 1 Choose Geometry Edit Divide Lines Near Point This option will divide the line at the point element on the line closest to the coordinates entered Enter the coordinates of the point that will divide the line In this example the coordin
99. he lines need to be the end of two surfaces Interior in the figure If there would be open edges on the geometry the lines would appear under a different colour and labelled Boundary or Isolated lines The lines at the entrance of the material Other are connected to more than two surfaces because they are also connected to the mould surfaces so they have a different colour this is correct The other lines are all interior in red This means that all the lines are connected to two surfaces the lines are not forming open boundaries or are isolated lines In other words this geometry consisting of points lines and surfaces is sound We can rotate and zoom the casting while we are in draw higher mode Now let s press Esc to go back to the geometry We have now a repaired geometry Lets move on to the next step GET STARTED TUTORIAL GRAVITY CASTING Step 3 MESH GENERATION Before start the meshing generation we will set the Meshing parameters as shown in Figure F 5 Go to Utilities Preferences and select the label Meshing Set all the parameters as shown in the figure Preferences General Graphical Meshing Exchange Fonts Format Grid Quadratic type Normal Quadratic Quadratic9 Unstructured mesher Surface RFast RSurf Volume Advancing front Delaunay Isosurface Automatic correct sizes None Normal Hard Unstructured size transitions
100. he mesh generated by about the mesh generated default 4 Use the option MeshView mesh boundary to see only the contour of the volumes meshed without their interior Figure 35 This mode of visualization may be combined with the various rendering methods Use this button to toogle between the geometry and the mesh VULCAN TUTORIALS teas F b ae sae Oe i a een Pee We r ee he E i a ea K Mae ce KE Oe Bi Ar Dey EAE KARY RE A ATS Eine PTAA E H ea a as ce te Pera Vows Ait ANG 7 ate Tim it Figure 35 Mesh visualized with the Mesh gt View mesh boundary option Visualize the mesh generated with the various rendering option in the Render menu located on the mouse menu B 24 VULCAN TUTORIALS Figure 36 Mesh visualized with Render gt Flat combined with Render gt Normal 5 2 Generating the mesh with assignment of size around points 1 Enter rotate angle 90 90 on the command line This way we will have a side view Figure 37 Side view of the part Another option equivalent to rotate angle 90 90 is Rotate Plane XY located on the mouse menu VULCAN TUTORIALS B 25 2 Choose Mesh Unstructured gt Assign sizes on points A window comes up in which to enter the element size around the point to be selected Enter 0 7 3 Select only the points on the wheel profile One way of doing this is to select the entire part and then cancel the se
101. he result is shown in Figure 44 Translate the new profile to the profile layer and eliminate the auxiliary lines and his points see the figure 45 Repeat the process explained in section 2 11 to create the wheel surface And using Geometry gt Create gt NURBS Surface gt By contour select it to create a NURBS surface Figure 455 Optimizing the design VULCAN TUTORIALS B 31 6 2 Modifying the profile of the hole 1 From now on we will work with the layer aux Select like a layer to use double click Choose Geometry gt Create Object Circle Enter 10 5 0 as the center point Enter a normal to the XY plane Positive Z and a radius of 1 With the tool Geometry gt Delete gt Surface in the Toolbox delete the surface of the circle so that only the line is left This way the option Geometry gt Edit gt Intersection Lines may be used to intersect the circle circumference Select only the circle and the two straight lines that intersect it Choose Copy from the Utilities menu and make two copies rotating the circle 45 degrees Using the intersection options delete the auxiliary lines leaving only the valid lines thus obtaining a quarter of the profile of the hole The result is illustrated in Figure 46 In the Copy window choose Mirror and Lines Make sure that the option Two Dimensions is highlighted Complete the mirror process obtaining a new hole this process was explained in section 3 2 Delete the auxil
102. he volumetric element must be entered In this example the value is 1 Progress in meshing z Meshing surface number 0 C W Mesh generated Meshed 6 surfaces of 6 Dialog window Num of Tetrahedra elements 9636 Meshing volume number 1 Num of nodes 2018 Meshed 0 volumes of 1 Number of nodes 2010 Number of elements 8592 Stop VULCAN TUTORIALS A 15 The mesh generated above is composed of tetrahedral elements of four nodes but Vulcan also permits the use of hexahedral eight nodded structured elements We will generate a structured mesh of the volume of the cube This is done by selecting in the right command bar Meshing gt Structured gt Volumes Again there are no structured meshes in casting problems You can skip this step and continue with the next tutorial Now select the volume to mesh and enter the number of partitions in its edges which will be created Then create again the mesh 7 Dialog window Enter value window a Mesh Generated Press OK to see it Q Enter number of divisions and assign it z Num of Prism elements 2220 to semi structured volumes Num of nodes 1452 Assign Cancel VULCAN TUTORIALS A 16 A ALAA AAA A AAZ Abbott itt AAA A A TAL AL AL TAL AL SALA AVA ATT ALT ALTA s Vint iv tie ti ie AWT A P R A A A YTV PA Oy LLI H O lt f structured meshes of 6 sided volumes lon O
103. iary lines Send to this lines to the layer profile and delete the layer aux Create the hole in the surface of the wheel using Geometry gt Edit Hole NURBS Surface Figure 466 A quarter of the new hole profile Figure 477 The surface of the new optimized design B32 VULCAN TUTORIALS 6 3 Creating the volume of the new design Repeat the same process as in section 4 3 1 In the Copy window choose Translation and Surfaces Enter two points that define a translation of 10 units for example 0 0 10 and 0 0 0 2 Choose Do Extrude Surfaces in the Copy window Click Select and select the surface of the wheel Press ESC 4 Choose Geometry gt Create gt Volume gt By contour and select all the surfaces of the part Figure 488 The volume of the optimized design GENERATING THE MESH FOR THE NEW DESIGN Generating the mesh for the optimized design is more complex In this geometry it is especially important to obtain a precise mesh on the surfaces around the hole and on the surfaces of the teeth VULCAN TUTORIALS B 33 Initially we will generate a simple mesh by default Then we will generate a mesh using Chordal Error to obtain a more accurate mesh 7 1 Generating a mesh for the new design by default 1 Choose the option Mesh Generate Mesh 2 Awindow comes up in which to enter the maximum element size for the mesh to be generated Leave the default value provided by VULCAN unaltered and
104. imation Default v Resize Close Figure G 38 Filling mater animation In Figure G 38 we can see the Animate window and the control buttons We can keep this window open while we rotate zoom in and zoom out the casting Let s explain the basic Animate controls ___GETSTARTEDTUTORIAL HPDG o Z o o o o G5 Basic Animate window controls Delay We can set this time in order to slow down the animation delay time is not the real time but a time we can increase in order to ease the visualization Step This box shows the real time step It shows the time in seconds since the filling process had begun Then we have the animation controls ooo these controls are the standard Play Pause Stop Fast Forward Rewind controls We can control the evolution of the animation with them G 56 GET STARTED TUTORIAL HPDC Let s say now that we want to see other phenomena for example turbulences formation highest filling velocities inside the casting velocities at which the advancing fronts encounter etc We will use a different representation to see these results Go to Vulcan results Filling vectors or select the button YS And again the animate window will show up The animation will show the velocity vectors inside the casting VELOCITIES 26 283 23 363 20 442 17 622 14 602 11 681 8 761 6 8407 2 9203 0 step 0 0253105 Display Vectors o
105. ion 180 degrees Repeat the process this time entering an angle of 180 degrees To return to the side view elevation choose Rotate gt Plane XY Choose Render gt Flat lighting from the mouse menu to visualize a more realistic version of the model Return to the normal visualization with Render gt Normal This option is more comfortable to work with C 12 VULCAN TUTORIALS Figure 15 The pipe with disks created by rotating the profile Ig NOTE To select the profile once the first rotation has been done first select all the lines and then delete those that do not form the profile Use the option Rotate gt Trackball from the mouse menu to rotate the model and facilitate the process of selection 3 3 Creating the union of the main pipes STERA o 1 Choose the option Zoom gt iIn from the mouse menu Magnify the right end of the model 2 Make sure the aux layer is visible 3 From the Copy window select Lines and Rotation Enter an angle of 120 degrees and from the Do extrude menu select Surfaces Since the rotation may be done in 2D choose the option Two Dimensions The center of the rotation is the tangential center VULCAN TUTORIALS C 13 2 xt pe i TA ppr HERNO 4 Ra by AL a ee kaz gt a J Eps mal a dry ee SS waaren ie EA pao hee Figure 16 The magnified right end of the model Click Select and select the four lines that define the right end of the pipe See 4
106. istorted elements Figure D 8 A machining groove done after the casting is also drawn in the part causing distorted elements It is convenient to delete the groove ANETE Az ARNS CN ee Be A ZA SEA KoA a KZ CO ZW A Wt Vee aw A Figure D 9 An engraved text Pocket in CATIA representing a part AN this text is causing distorted and small elements and it is convenient to delete it ig NOTE There is also a Mesh quality tool that can be used to check the mesh For more information see Meshing section on Vulcan manual GET STARTED TUTORIAL GEOMETRY CORRECTION Figure D 10 Element distortion caused by small radii edge fillets in some zones of the part Even though all these mesh distortions can be corrected with Vulcan there are some measures that we can take before we export the part into an IGES file Machining operations All the machining operations made after the casting over the part slots grooves can be excluded before we export the part Small radii and small chamfers We can also exclude the small fillets and chamfers of the part Texts and logos embossed or engraved They usually don t represent the body of the part and generate distortions GET STARTED TUTORIAL GEOMETRY CORRECTION To do this we go back to CATIA and have a delete the unneeded operations by using the tree Parents Delete exclusive parents 8 Delete all children Py More gt gt Delete
107. k Open the result should look like this uco fies yie Geoenet bie Dra Me Workshop Calculate Hep OB DIBA DSe Gaeds 2910 bs eari IE All EAE E PA 8 Bl Q lez Somen EN Pi Oats E 7a Mohrig 4i Fies E ka Vew Dg a idise al amp d Settings Jose Arfonio Mis documentos Quantach Michale Zan a Bige na Er g escape Rg A aa nE P Collapse gaometry Time seconds created 415 i ImpcetT olerance 0 000010 x BT XK JAR SOT X Nome jejyolrul miei ude oye v K ai Aia pe i P Qose y bs Pick LEFTMOUSE to desplace view ESC m quit present mouse wheel zooms l Pick LEFTMOUSE to desplace view ESC t guin 5 Commend a Figure F 5 IGES read Close the info window and have a look at the geometry of Figure F 55 by right clicking and doing rotate trackball and zoom in and out GET STARTED TUTORIAL GRAVITY CASTING Once done with looking at geometry we will start working with different layers one layer for the casting one layer for the mould etc Click on the Layers icon The following window will appear Figure F 66 Uaerkeady Name COTEU Tr v a Figure F 6 Layers control window GET STARTED TUTORIAL GRAVITY CASTING Perform the following operations e Click on New button and create a new layer Figure F 7 Layer selection and layer to use e Select the layer Layer0 change the name cast se
108. l Figure F 3 Vulcan problemtype window Click OK and the process bar will open automatically it will be used and described in detail in the present tutorial Now that we have the Vulcan pre process interface opened and set lets begin with the first step GET STARTED TUTORIAL GRAVITY CASTING Step 1 READ AN IGES FILE Before reading the IGES file we are going to set Vulcan parameters in the optimal configuration for importing this type of files In the main menu click on Utilities Preferences The following window will open Preferences General Graphical Meshing Exchange Fonts Format Grid Import v Automatic collapse after import v Automatic import tolerance value Importtolerance 0 00048708 Collapse Ignoring layers Each layer separately v IGES Curve on surface from 3D IGES Create all in layer to use Export v IGES B Rep output style Figure F 4 Setting importing preferences The following checkboxes must be selected in Figure F 4 M Automatic collapse after import M Automatic import tolerance value Accept the changes and Close the window GET STARTED TUTORIAL GRAVITY CASTING Now we are ready to import IGES files Let s import a sample file This file can be downloaded from the VULCAN web page hitp www quantech es support vulcan aspx Click the first icon on the process bar and read the following file Rev_gravity_V8 igs Select it and clic
109. l not click on the icon Exiting Vulcan while is still calculating When the pre process is over and we are calculating a process we can exit Vulcan application but without interrupting the calculation fl Dialog window Are YOU sure you want to terminate the process borrarb started at Fri Mar 26 12 00 33 jes Figure F 36 Exiting Vulcan while is still calculating Click No and Vulcan will exit We can open Vulcan later during or after the calculation The computer of course must remain on GET STARTED TUTORIAL GRAVITY CASTING Step 9 POST PROCESS Post process means the visualization of the simulation results this is perhaps the most important step of all the casting simulation steps here is where we read and analyze the simulation results Once the calculation is finished we can visualize the results of this simulation There are many different ways to do it like colour maps vectors iso surface curves virtual thermocouples etc Figure F 37 shows the window that appears once calculation step is finished we can directly access to post process by clicking on Postprocess button U Process window U Process info Process borrarb started at Fri Mar 26 i 12 09 10 has finished Postprocess Output view Terminate Start Stark remote Remote Figure F 37 Process info Another way to switch between pre and post process is by clicking the toggle icon S Ja NOTE Every time
110. l start U Process window Project Start time UID borrarS Friar 26 12 00 33 2964 Calculating Output view Terminate Start remote Remote Figure F 34 Calculation window GET STARTED TUTORIAL GRAVITY CASTING We can view the Output view by clicking the icon and see the calculation status and also interrupt and cancel the calculation by Terminate the process make changes and Calculate again Close the window OUTPUT VIEW Once the window is closed we can still access to the output view by clicking on the icon And we will see the calculation process output info for borrar2 1 Thu Mar 29 16 11 43 L2_VELOC 0 436E 02 NUM ITERS FILLED VOLUME 0 500267E 07 CPU_TIME 0 196249E 02 Elapsed Time Estimated Remaining Time STEP 4 TIME 0 46150E 04 L2_VELOC 0 877E 02 NUM ITERS FILLED VOLUME 0 597962E 07 CPU_TIME 0 258650E 02 Elapsed Time Estimated Remaining Time Ooh 1 o 46 m 19 STEP 5 TIME 0 70574E 04 L2_VELOC 0 104E 01 NUM ITERS FILLED VOLUME 0 732468E 07 CPU_TIME 0 320738E 02 Elapsed Time Estimated Remaining Time STEP 6 TIME 0 10420E 03 Figure F 35 Output view GET STARTED TUTORIAL GRAVITY CASTING TERMINATE PROCESS If we want to change parameters and calculate again we would click on the last icon This icon will terminate the process In the example we will leave the computer calculating and wait for the end of calculation We wil
111. lane Plane 1 Plane 2 Figure G 16 The Process type Symmetries window Now the gravity casting process is defined click Close to continue to the next step J4 NOTE All the changes made will be saved upon clicking on the Close button GET STARTED TUTORIAL HPDC G 31 Step 5 FOUNDRY COMPONENTS DEFINTION Click on the Components definition icon The following window will open Figure G 17 Define foundry components Layers Available Assigned cast mould Parameters Material properties Material group foe Material C New Database Edit Temperature Coating lnitial temperature C 1500 0 Calculate ingate area M Use coating Conduction Cal m C 0 8 Thickness mm 100 0E 6 Figure G 17 Foundry components definition G 32 ET STARTED TUTORIAL HPDC First we have to assign each layer to the corresponding foundry component On the example shown the Part component is highlighted on the tree In the Available window select cast and click on the Icon The cast layer will move to the Assigned window Now select the Material group and specific material from the database and set a temperature of 650 Degrees Celsius as shown in Figure G 18 Define foundry components Layers Available Assigned eas mold cast EN Mould Mould Parameters Material properties Material group Aluminium Z Material C New Database AISi 7Mgq v on Edit Current mat
112. lect only the lines of the wheel profile using the same process as in section 5 2 VULCAN TUTORIALS B 27 Figure 41 Selected lines of the wheel profile 4 Choose Mesh Generate mesh A window appears asking if the previous mesh should be eliminated Click Yes 5 Another window comes up in which to enter the maximum element size Leave the default value unaltered 6 A greater concentration of elements has been achieved around the lines selected In contrast to the case in section 5 2 this mesh is more accurate since lines define the profile much better than points do Figure 42 B 28 VULCAN TUTORIALS Figure 42 Mesh with assignment of sizes around lines 6 OPTIMIZING THE DESIGN OF THE PART The part we have designed can be optimized thus achieving a more efficient product Given that the part will rotate clockwise reshaping the upper part of the teeth could reduce the weight of the part as well as increase its resistance We could also modify the profile of the hole in order to increase resistance in zones under axe pressure To carry out these optimizations we will use new tools such as NURBS lines The final steps in this process will be generating a mesh and visualizing the changes made relative to the previous design This example begins with a file named optimizacion gid This file can be downloaded from the VULCAN web page hitp www quantech es support vulcan aspx VULCAN TUTORIALS B 29 6 1 Modifying the pr
113. lecting the Rename button e Select the layer Layer1 change the name mould selecting the Rename button Tg NOTE The selected layer is highlighted in black After selecting a layer by simply clicking on it we can delete it rename it change its color turn it on and off send elements to it etc The layer to use instead is the layer with the checkmark in the layer to use we can create geometry delete it etc in the drawing Summary Selected is to make changes by using layers window and layer to use is the layer used to create delete or modify geometry We can change the layer to use by doubleclick GET STARTED TUTORIAL GRAVITY CASTING e Be sure that Layer to use is cast it says so beside the button and there is a checkmark v in the layer name e Select the layer mould and click on Send To and then Surfaces e Go to the casting geometry and select the six surfaces that form the exterior of the mould e Turn off the layer mould e Select the layer cast and Send To again select all the cast surfaces and press Esc e Close the layers window The resulting geometry at this moment shall look like Figure F Vulcan Project UNNAMED E ee Files View Geometry Utilities Data Mesh Workshop Calculate Help OB Sl SoCNwlBAlS amp Ses B o Z2DRDVEWUS LCKBRSROOMNEG SS p igs NW i i M oe J N OG i CH lt S A OWM OOIE E NN Lae fa itr od fed
114. lection of the points that form the prism hole Press ESC two times to conclude the selection process Figure 38 The selected points of the wheel profile 4 Choose Mesh Generate mesh 5 A window comes up asking if the previous mesh should be eliminated Figure 39 Click Yes Another window appears in which to enter the maximum element size Leave the default value unaltered Figure 39 6 A third window shows the meshing process Once it has finished click View mesh to visualize the resulting mesh fa 8 VULCAN TUTORIALS Figure 40 Mesh with assignment of sizes around the points on the wheel profile A greater concentration of elements has been achieved around the points selected Choose Geometry View Geometry to return to the normal visualization 5 3 Generating the mesh with assignment of size around lines 1 Open the Preferences window which is found in Utilities Bring forward the Meshing card In this window there is an option called Unstructured Size Transitions which defines the size gradient of the elements A high gradient number enables the user to concentrate more elements on the wheel profile To do this select a gradient size of 0 8 Click Accept and close Choose Mesh Reset mesh data to delete the previously assigned sizes from section 5 2 Choose Mesh Unstructured Assign sizes on lines A window comes up in which to enter the element size around the lines to be selected Enter size 0 7 Se
115. ls about importing and exporting see Meshing section in Vulcan user s Manual GET STARTED TUTORIAL GEOMETRY CORRECTION Now we will have a look over the imported part we see it in render view we check the higher entities we see the details etc Note that this part is only a surface geometry Project UNNAMED Elles View Geometry tities Data Mesh Workshop Calculate Help COCdIBVSVIBAIWS Sw e 8 eAANAVPSEAWTSCLKARSRECSLNeSS gs a 35 ft Er XE 2 a 7 A ERA z y Pick LEFT MOUSE to desplace view E 5C to qui i present mouse wheel zooms Pick LEFTMOUSE to desplace view ESC to quit z a sanner vom same Select type of artiy to daw Pies Escape to have Diandng hagherentiies Prez Excape to nava L Comment f Figure D 3 Renderizing and Higher entities of the imported part GET STARTED TUTORIAL GEOMETRY CORRECTION This part as we see in Figure D 3 is a set of closed surfaces as we see when we check with higher entities all the surface entities are well connected and there are no volumes generated Due to the characteristics of Vulcan mesher surface mesh will be generated prior to volume mesh furthermore volume tetrahedral mesh will be based on the surface triangular mesh and will be generated advancing from this surface mesh so it is always necessary for complex parts to firstly generate the surface mesh in order to check its quality regarding to distortion
116. ment type gt Reset mesh data Draw gt Mesh options from model Figure G 6 Mesh generation screen ___GETSTARTEDTUTORIAL HPDC GG The automatic assigned size of the mesh is 20 5 change this value to 9 Mesh generation Enter size of elements to be generated fF C Get meshing parameters from model and click OK The result will be like this Figure G 7 Non uniform triangle mesh Tg NOTE We can toggle between geometry view and mesh view by clicking on the icon and also change normal view to render view by right clicking on the geometry and selecting Render Flat or Render Normal G 2 ET STARTED TUTORIAL HPDC We can see in Figure G 7 that elements are not too uniform in order to be acceptable Let s decrease the size of the elements to obtain a more uniform mesh Go to Mesh Generate Mesh And set a mesh size of 5 The result should be like in Figure G 8 Dialog window i O Mesh generated Num of Triangle elements 13532 Num of nodes 6746 Figure G 83 Mesh generation ___GETSTARTEDTUTORIAL HPDG _ o o O y OG Compare the results of Figure G 7 and Figure G 8 to see that in order to improve the mesh quality we have to decrease the elements size The mesh in Figure G 8 is a more uniform mesh but the number of elements had increased Le s now return to geometry by clicking and generate the volume and tetrahedral elements Go to Geometry
117. n Apply Close And create point 2 in the same way introducing its coordinates 10 0 0 in the Coordinates Window The last step in the creation of the points as well as any other command is to press Escape either via the Escape button on the keyboard or by pressing the central mouse button Select Close to close the Coordinates Window and go to View gt Zoom gt Frame in order to see the two points created Now we will create the line that joins the two points Choose from the Top Menu Geometry gt Create Straight line Option in the Toolbar shown below can also be used Next the origin point of the line must be defined In the Mouse Menu opened by clicking the right mouse button select Contextual Join C a VULCAN TUTORIALS A 5 Ja NOTE With option Join a point already created can be selected on the screen The command No Join is used to create a new point that has the coordinates of the point that is selected on the screen We can see that the cursor changes form for the Join and No Join commands Cursor during use of Join command Cursor during use of No Join command Now choose on the screen the first point and then the second which define the line Finally press Escape to indicate that the creation of the line is completed Ja NOTE It is important to note that the Contextual submenu in the Mouse Menu will always offer the options of the command that is currently being used In this case th
118. n steps here is where we read and analyze the simulation results Once the calculation is finished we can visualize the results of this simulation There are many different ways to do it like colour maps vectors iso surface curves virtual thermocouples etc Figure G 36 shows the window that appears once calculation step is finished we can directly access to post process by clicking on Postprocess button output info for borrar Mon Apr 23 12 47 06 El CPU TIME 939 422 RATIO TOLER 11 7 INTERVAL 1 ISTEP 89 IITER 2 CPU TIME 941 107 RATIO TOLER 1 379E 13 gt gt gt gt gt gt gt END OF STEP output info ff Process window THERMAL PARTITIG AT Process info E INTERVAL Elapse CPO LINE Process borrar started at Mon zir Apr 23 12 47 06 has finished _ INTERVAL STEP CPU TIME L2 STEP FIL cru Elapseq Estimal comeT END OF J step 4 Output view Terminate L2_ FIL al Stat Star remote Remote Close m CPU Close Elapseq Estima tea rumearanyg samecs a a T STEP 179 TIME 0 56324E 01 L2_VELOC 0 539E 01 NUM ITERS 9 NORMAL END OF RUN EXECUTION J De Close Figure G 36 Process info GET STARTED TUTORIAL HPDC G 53 Another way to switch between pre and post process is by clicking the toggle icon S The first step in results visualization is to load results of any foundry operation Filling thermal solidific
119. nd select the vertical line segment starting at the origin of coordinates Press ESC 8 Choose Geometry gt Edit gt Intersection gt Lines Select the two last lines created and the vertical line segment coming down from the tangential center See Figure 12 Press ESC C 10 VULCAN TUTORIALS Figure 12 Selecting the lines to intersect 9 Choose Geometry gt Delete gt All Types This tool may also be found in the VULCAN Toolbox Select to delete the lines and points beyond the vertical that passes through the tangential center Press ESC The result should look like that shown in Figure 13 Figure 13 Profile of the pipe and the auxiliary lines VULCAN TUTORIALS C 11 3 2 Creating the volume by revolution STEP 4 B i 2 pi Rotation of the profile will be carried out in two rotations of 180 degrees each This way the figure will be defined by a greater number of points From the Copy window select Lines and Rotation Enter an angle of 180 degrees and from the Do extrude menu select Surfaces The axis of rotation is that defined by the line that goes from point 0 0 to point 200 0 Enter these two points as the First Point and Second Point Be sure to enter 1 in Multiple Copies Click Select For an improved view when selecting the profile click Off the aux layer Press ESC when the selection is finished The result should be that illustrated in Figure 14 7 Figure 14 Result of the first step in the rotat
120. new problemtype Yoy are going to load problemtype Wulcan what do you want to do f Update to new problemtype All data information materials conditions data will be lost f Transform to new problemtype Data will be converted to new problermtype if possible Some data may be lost Cancel Figure G 3 Vulcan problemtype window Click OK and the process bar will open automatically it will be used and described in detail in the present tutorial Now that we have the Vulcan pre process interface opened and set lets begin with the first step GET STARTED TUTORIAL HPDC Step 1 READ AN IGES FILE Before reading the IGES file we are going to set Vulcan parameters in the optimal configuration for importing this type of files In the main menu click on Utilities Preferences The following window will open Preferences General Graphical Meshing Exchange Fonts Format Grid Import MV Automatic collapse after import V Automatic import tolerance value Collapse Ignoring layers C Each layer separately V IGES Curve on surface from 3D IGES Create all in layer to use Export V IGES B Rep output style Reset Close Figure G 4 Setting importing preferences The following checkboxes must be selected in Figure G 4 M Automatic collapse after import M Automatic import tolerance value Accept the changes and Close the window ___GETSTARTEDTUTORIAL H
121. nodded triangular elements Gd NOTE Vulcan meshes by default the entity of highest order with which it is working Vulcan allows the user to concentrate elements in specified geometry zones Next a brief example will be presented in which the elements are concentrated in the top right corner of the square This operation is realized by assigning a smaller element size to the point in this zone than for the rest of the mesh Select the following sequence Mesh gt Unstructured gt lt Assign sizes on points The following dialog box appears in which the user can define the size A 10 VULCAN TUTORIALS U Enter value window points l l l Q Enter size to assign to points 0 0 to lines unassign surfaces volumes Assign We enter the size choose the right superior point and press escape two times We must now regenerate the mesh Mesh gt Generate Mesh canceling the mesh generated earlier and we obtain the following As can be seen in the figure above the elements are concentrated around the chosen point Various possibilities exist for controlling the evolution of the element size which will be presented later in the manual 3 CREATION AND MESHING OF A VOLUME We will now present a study of entities of volume To illustrate this a cube and a volume mesh will be generated Without leaving the project save the work done up to now by choosing Files gt Save and return to the geometry last create
122. ns for generating meshes and visualizing the result C 2 VULCAN TUTORIALS This page is intentionally left blank VULCAN TUTORIALS C 3 1 WORKING BY LAYERS Various auxiliary lines will be needed in order to draw the part Since these auxiliary lines must not appear in the final drawing they will be in a layer apart from the one used for the finished model 1 1 Creating two new layers Layers 1 Open the layer management window which is found in the Utilities gt Layers menu JTa amp e amp Reax2ey 2 Create two new layers called aux and ok Enter the name for each layer in the Layers window Figure 1 3 Choose aux as the activated layer DoubleClick Figure 1 The Layers window C 4 VULCAN TUTORIALS 2 CREATING THE AUXILIARY LINES The auxiliary lines used in this project are those that make it possible to determine the center of rotation and the tangential center which will be used later to create the model 2 1 Creating the axes STEP 1 g 1 Choose the option Line which is located in Geometry gt Create Line 2 Enter the coordinate 0 0 on the command line 3 Enter the coordinate 200 0 on the command line 4 Press ESC to indicate that the process of creating the line is finished 5 Again choose Line Draw a line between points 0 25 and 200 25 The result is shown in Figure 2 Figure 2 6 Goto the Copy window Figure 4 which is found in Utilities gt Copy
123. nt components for different operations etc To continue with the example we leave the default selection and then we are going to view and set all the parameters for both operations We have to go trough all the labels and change the default parameters for those of interest In our example we will see all the options and a short explanation of the principal parameters GET STARTED TUTORIAL GRAVITY CASTING In strategy label Figure F 2429 we set the Flow rate for gravity filling default 2 dm Sec and we decide whether to use tilt pouring or not In case of using tilt pouring we have to select it and enter all the options Change flow rate to 0 4 dm Sec and continue Click to the next label We also can calculate by filling time or by gravity in this case we have to assign the height between the spoon and the mould Another parameter to assign is the Mould Surface Finish We have 4 values to decide the roughness of the mould between low and high Define operations Filling Foundry comps Strategy Contacts HTC Env Special Output AXN Therman General parameters Mould surface finish Roughness Low specular 4 Flow rate Value dm 3 s 0 4 C Filling time C By gravity Without mould Tilt pouring M Run without mould M Use tilt pouring Figure F 24 Strategy label GET STARTED TUTORIAL GRAVITY CASTING Define operations Filling Foundry comps Strategy Contacts HTC Erw Special Output A
124. ofile 1 Choose the option Open from the Files menu and open the file optimizacion gid 2 The file contents appears on the screen In order to work more comfortably select Zoom In thus magnifying the image This option is located both in the VULCAN lt Toolbox or in the mouse menu under Zoom Figure 43 Contents of the file optimizacion gid 3 Make sure that the aux layer is activated doubleckick 4 Choose Geometry Edit Divide Lines gt Num Divisions This option divides a line into a specified number of segments 5 A window comes up in which to enter the number of partitions 8 Select the line segment from the upper part of a tooth Figure 43 Using the option Geometry Create Point create a point at the coordinates 40 8 5 8 Choose Geometry Create NURBS line to create a NURBS curve The NURBS line to be created will pass through the two first points which have been created on dividing the line at point 40 8 5 and by the two last points of the divided line VULCAN TUTORIALS Figure 44 Optimizing the design Select the first point through which the curve will pass To do this use Join C a located in Contextual on the mouse menu One at a time select the rest of the points except the last one Use Join C a each time in order to ensure that the line passes through the point Before selecting the last point choose Last Point in Contextual on the mouse menu Then finish the NURBS line T
125. oint evolution Temperatures or select the button And select a point in the middle of the casting Figure G 43 Point selection The result will be Gee ET STARTED TUTORIAL HPDC TEMPERATURES TIME_STEP Figure G 44 Virtual thermocouple in the casting __GETSTARTEDTUTORIAL HPDC o o G In the previous temperature images we cannot see the casting phase change from liquid to solid In order to see this and for example the effectivity of our riser system the evolution of the solid phase the last points in the casting to reach solid state etc we will do the following Go to Vulcan results Solid fraction evolution or select the button Figure G 45 Solid fraction evolution Here we have the liquid fraction of the casting is plotted in red and the solid part of the casting disappears while is forming so we only see the remaining liquid parts inside the casting as it solidifies during the animation The last points remaining in red should be the risers Gees GET STARTED TUTORIAL HPDC Finally we will plot the solidification modulus of our casting The modulus is the volume to surface ratio of the casting and it can also be seen inside the casting by making cuts Let s go back to Figure G 49 and make again the temperature evolution and then again temperature in cut Once we have the results like in Figure G 42 go to View results Contour fill Solidif Modulus The
126. on Problem dimension Figure H 15 The Process type General window 28 GET STARTED TUTORIAL LPDC In the Symmetries label Figure H 16 we have to define the symmetry planes created if there are no planes of symmetry simply leave No planes selected Define the problem Process type General Symmetries Number of planes 1 Plane 2 Plane Figure H 16 The Process type Symmetries window Now the gravity casting process is defined click Close to continue to the next step J4 NOTE All the changes made will be saved upon clicking on the Close button 29 GET STARTED TUTORIAL LPDC Step 5 FOUNDRY COMPONENTS DEFINTION Click on the Components definition icon The following window will open Figure H 17 Define foundry components Layers Available Assigned cast mould Parameters Material properties Material group Material C New hii Database Edit Temperature Coating Initial temperature C 1500 0 M Use coating Conduction Calm C Thickness mm 100 0E 6 Figure H 17 Foundry components definition 30 GET STARTED TUTORIAL LPDC First we have to assign each layer to the corresponding foundry component On the example shown the Part component is highlighted on the tree In the Available window select cast and click on the Icon The cast layer will move to the Assigned window Now select t
127. ons 47 GET STARTED TUTORIAL LPDC Now following the column of icons shown in Figure H 31 we first saved the project and then Calculate it The calculation time will depend upon the complexity of the problem The calculation window will look like this Calculate the simulation Calculate General options Solver accuracy Low High Select operation Calculated operations Name From operation Filling Name To operation w r Figure H 39 Calculation window Select From operation filling To operation Thermal1 and click OK The calculation will start Process window Project Starttime UID Priority b1 Tue Apr 24 12 26 44 3084 Normal Cal Output view Terminate Start remote Remote Close Figure H 320 Calculation window 48 GET STARTED TUTORIAL LPDC We can view the Output view by clicking the icon and see the calculation status and also interrupt and cancel the calculation by Terminate the process make changes and Calculate again Close the window OUTPUT VIEW Once the window is closed we can still access to the output view by clicking on the icon And we will see the calculation process output info for current 1 STEP 77 TIME 0 29441E 00 L2_VELOC 0 760E 01 NUM ITERS FILLED VOLUME 0 170478E 04 CPU_TIME 0 186062E 03 Elapsed Time Oh 3m 6 Estimated Remaining Time Oh Om 0 STEP 78 TIME 0 29510E 00 L2_VELOC 0 755E 01 NUM ITERS FIL
128. ontacts HTC Env Special Output HTC environment properties Identifier Foundry component HTC environment 73 Part Env Part HTC Aluminium Mould Env Mould HTC Gray lron Add Modify HTC environment curve Component HTC environment curve C New Database kd x Current HTC Enw Figure H 29 HTC Environment label We have pre selected the same options as for the filling analysis Continue to the next label 45 GET STARTED TUTORIAL LPDC Define operations SSS X Filling Foundry comps Strategy Contacts HTC Env Special Output Nim Thermal results Result by Output frequency steps M Temperature M Solid fraction Figure H 30 Thermal Special Output label M Solidification modulus Temperature rate In this label we define the thermal results that we are going to visualize on the post process In the example leave Temperature Solid fraction Solidification modulus and Solidification time Now that we have defined all the problem parameters click on the Close button The parameters will be saved 46 GET STARTED TUTORIAL LPDC Step 7 SAVE PROJECT Before start the calculation don t forget to save the project Click on Save icon Tg NOTE the filename must not contain spaces or symbols Step 8 CALCULATION Save Calculate Output view Kill process Figure H 31 Calculate Output view and kill Process ic
129. pipe section must also measure 40 length units the vector is defined by points 0 0 0 and 0 0 40 5 From the Do extrude menu select the option Surfaces 6 Click Select to select the lines that define the cross section of the second pipe Press ESC to conclude the selection Figure 25 A rendering of the two intersecting pipes C 18 VULCAN TUTORIALS 4 3 Creating the lines of intersection STEP 10 B 1 Choose Geometry gt Edit gt Intersection gt Surface surface 2 Select the outer surfaces of each pipe thus forming the intersection of the two surfaces selected 3 Repeat the process to obtain the four lines of intersection Figure 26 Creating lines of intersection between the surfaces VULCAN TUTORIALS C 19 4 6 Deleting surfaces and lines STEP 11 1 Choose Geometry gt Delete gt Surface Select the interior surfaces Fig 27 Press ESC to conclude the process of selection 2 Choose Geometry gt Delete gt Line Select the lines defining the end of the second pipe foreground that are still inside the first pipe background Figure 27 Surfaces to be deleted STEP 12 4 7 Closing the volume sa 1 The model now has three outlets The two outlets farthest from the origin of coordinates must be closed The third will be connected to the rest of the piece when the T junction is imported 2 Choose Geometry gt Create gt NURBS Surface gt By contour and select the two lines defining the outlet in t
130. ple each circumference must be defined between two points Figure 23 Figure 22 The result of the first Figure 23 The combined result of the first rotation and the second rotation of 180 degrees thus obtaining the profile of the pipe section 6 From the Copy window choose Lines and Translation In First Point and Second Point enter the points defining the translation vector Since the pipe section must measure 40 length units the vector is defined by points 0 0 0 and 40 O 0 7 From the Do extrude menu choose the option Surfaces 180 degree rotation VULCAN TUTORIALS C 17 8 Click Select to select the lines that define the cross section of the pipe Press ESC to conclude the selection process Figure 24 Creating a pipe by extruding circumferences 4 2 Creating the other pipe section STEP 9 g 1 Choose Geometry gt Create gt Point and enter points 20 9 and 20 11 Press ESC to conclude the creation of points 2 From the Copy window select Points and Rotation Enter an angle of 180 degrees and from the Do extrude menu select Lines Since the rotation may be done on the xy plane choose Two Dimensions The center of rotation is 20 0 0 3 Click Select and select the two points just created Repeat the process this time entering an angle of 180 degrees 4 From the Copy window select Lines and Translation In First Point and Second Point enter the points defining the translation vector Since this
131. quantech es support vulcan aspx Figure 3 Collapsing the model Figure 4 Repairing model Figure E 1 IGES importing progress VULCAN TUTORIALS Info window 07 18 21 9 Minimum Resolution 1e 008 Approximate Maximum Coordinate 260 544 Organization QUANTECH ATZ Specification Yersion 5 2 lapse geometry Time 2 second s created 5638 points 3861 lines 19 surfaces 0 volumes ImportT ole rance 0 002060 Figure E 2 Importing process information 3 After the importing process the IGES file that VULCAN has imported appears on the screen we l E 4 p imig HDR i Wy i he Figure E 3 File tutorial_importi5 igs imported by VULCAN Select Right button gt Render gt Flat Figure E 4 Renderization of the geometry in which we can see pieces lying on different layers VULCAN TUTORIALS U Preferences General Graphical Meshing Exchange Fonts Format Grid Import W Automatic collapse after import Automatic import tolerance value Import tolerance 0 1 0000000000000001 Collapse f gnoring layers f Each layer separately IGES Curve on surface from 3D GES Create all in layer to use Export W IGES B Rep output style Heset Close Figure 5 The Preferences window 4 Go to the automatic import tolerance value and change the default value to 0 1 in order to collapse some lines that we cannot collapse with the previous v
132. r view by right clicking on the geometry and selecting Render Flat or Render Normal 18 GET STARTED TUTORIAL LPDC Go to Mesh Generate Mesh And set a mesh size of 2 Mesh generation Enter size of elements to be generated a Get meshing parameters from model The result should be like in Figure H 8 Figure H 8 Mesh generation 19 GET STARTED TUTORIAL LPDC Compare the results of Figure H 8 and Figure H 7 and look at the notorious difference at the element sizes Figure H 8 represents much better the real casting geometry Let s now return to geometry by clicking and generate the volume and tetrahedral elements Go to Geometry Create Volume By contour or click the Create volume icon gi i The following will appear in the command line Enter surfaces to define volume ESC to leave Select all the surfaces of the casting with a selection window Added 114 new surfaces to the selection Enter more surfaces ESC to leave press Esc Created 1 new volume Enter more volumes And now press Esc again Leaving volume generation Now regenerate a mesh with size of 1 in order to obtain a mesh of the volume The result will look again as in Figure H 8 Generating the mould mesh Return to geometry view Click on Layers icon and turn on the layer mould With the layer mould selected click on the Layer to use icon Now we will generate a volume
133. rocess we are going to calculate Click on define the main process characteristic the 7 icon A window with 3 labels will appear In the Process type label select High pressure as shown in Figure G 14 6 28 ET STARTED TUTORIAL HPDC Define the problem Process type General Symmetries Select process type l Gravity M High pressure Low pressure M LostFoam Figure G 14 The Process type window Once this step is taken Vulcan adjusts all the internal parameters and the remaining icons to this particular type of process ___GETSTARTEDTUTORIAL HPDC _ O Z oO o Y GW In the General label we have a set options to define units gravity direction with respect to the coordinate system compass environment temperature etc Set the gravity direction to Y and the Environment temperature to 25 Degrees Celsius as shown in Figure G 15 Define the problem Process type General Symmetries Gravity constant 9 61 Environment temperature 25 0 Model units C Meter C Centimeter Millimeter Gravity direction Problem dimension o Figure G 15 The Process type General window G 30 GET STARTED TUTORIAL HPDC In the Symmetries label Figure G 16 we have to define the symmetry planes created if there are no planes of symmetry simply leave No planes selected Define the problem Process type General Symmetries Number of planes f No planes 1 Plane C 2P
134. rs window The auxiliary lines will have been eliminated and the profile layer will contain only the definitive lines 3 Click the right button mouse over the layer profile and select Send To choose Lines in order to select the lines to be translated Select only the lines that form the profile Figure 14 To conclude the selection process press the ESC key or click Finish in the Layers window B 12 VULCAN TUTORIALS Figure 14 Lines to be selected 2 10 Deleting the aux layer 1 Click Off the profile layer 2 Choose Geometry gt Delete All Types or use the VULCAN Toolbox 3 Select all the lines that appear on the screen The click and drag technique may be used to make the selection 4 Press ESC to conclude the selection of elements to delete 5 Select the aux layer in the Layers window and click Delete Ja NOTE When a layer is clicked Off VULCAN gives note of this From that moment on whatever is drawn does not appear on the screen since it goes on the hidden layer Ja NOTE To cancel the deletion of elements after they have been selected open the mouse menu go to Contextual and choose Clear Selection Ja NOTE Elements forming part of higher level entities may not be deleted For example a point that defines a line may not be deleted Ja NOTE A layer containing information may not be deleted First the contents must be deleted VULCAN TUTORIALS B 13 2 11 Rotating and obtaining the final profile
135. select the button LX Select Cut xz plane button and then draw a line dividing the mould horizontally in two equal halves Selecting the Show cut sections the result will be 58 GET STARTED TUTORIAL LPDC Graph Options Graph options _____ eez m Cut plane e Show cut sections ce Point evolution i Toogle mesh graph view a Clear graphs Ey Graph manager Figure H 41 Temperature in cut On the figure we can see the temperature evolution of both the casting and the mould in the Cut xz plane By pressing the Play button on the animate window we can see all the temperature evolution during solidification select render normal to see a better resolution 59 GET STARTED TUTORIAL LPDC Now we will add a virtual thermocouple in a point in the middle of the casting Go to E3 View results Graphs Point evolution Temperatures or select the button And select a point in the middle of the casting Figure H 42 Point selection The result will be 60 GET STARTED TUTORIAL LPDC Figure H 43 Virtual thermocouple in the casting 61 GET STARTED TUTORIAL LPDC In the previous temperature images we cannot see the casting phase change from liquid to solid In order to see this and for example the effectivity of our riser system the evolution of the solid phase the last points in the casting to reach solid state etc we will do the following Go to Vulcan
136. simulate one by one Leave Filling and click OK and then enter on the same previous icon and select Thermal solidification operation G 38 GET STARTED TUTORIAL HPDC The result should look like this Define operations Foundry comps Strategy Contacts HTC Env Special Output Available foundry components Selected foundry components Mould Part Figure G 22 Operations definition In Figure G 22 we can see that all the foundry components are assigned by default to the filling and solidification operations In Figure G 17 we created those foundry components Here we have the option of changing the foundry components selecting different components for different operations etc To continue with the example we leave the default selection and then we are going to view and set all the parameters for both operations We have to go trough all the labels and change the default parameters for those of interest In our example we will see all the options and a short explanation of the main parameters GET STARTED TUTORIAL HPDC G 39 In strategy label Figure G 29 we set the piston diameter and we build the Time vs Velocity curve for the specific injection machine On the example we set a piston diameter of 70 mm and change the piston velocity to 2 5 m s for times 0 and 0 5 seconds as shown in figure Define operations s Saat SR k Filling AY Therman Foundry comps Strategy Con
137. t By contour and select the four lines that define the opening of the pipe Figure 21 Press ESC Go to Geometry Edit gt Collapse Model in order to collapse the isolated lines From the Files menu choose Save in order to save the file Enter a name for the file and click Save Figure 21 Opening at the end of the pipe C 16 VULCAN TUTORIALS 4 CREATING THE SECOND COMPONENT PART THE T JUNCTION Now an intersection composed of two pipe sections will be created in a separate file and the surfaces will be trimmed Then this file will be imported to the original model to create the entire part 4 1 Creating one of the pipe sections STEP 8 4 1 Choose Files gt New thus starting work in a new file 2 Choose Geometry gt Create gt Point and enter points 0 9 and 0 11 Press ESC to conclude the creation of points 3 From the Copy window select Points and Rotation Enter an angle of 180 degrees and from the Do extrude menu select Lines The axis of rotation is the x axis Enter two points defining the axis one in First Point and the other in Second Point for example 0 0 0 and 100 0 0 Figure 22 4 Click Select and select the two points just created 5 Repeat the process this time entering an angle of 180 degrees thus creating the profile of the pipe section with a second rotation of 180 degrees The rotation could have been carried out in only one rotation of 360 degrees However in the present exam
138. tacts HTC Env Special Output General parameters Mould surface finish Roughness Low specular 4 2 Piston diameter mm 70 0 Value s Calculate piston velocity profile Velocity defined by Velocity curve Manual pointfase change Velocity curve Table Graph Points Time s Velocity m s Time vs velocity 1 oo 25 2 1 833 1 667 1 5 0 0 08333 0 166 0 25 03333 0 4167 05 Ux Without mould Vacuum options M Run without mould M Use vacuum Figure G 29 Strategy label G ET STARTED TUTORIAL HPDC Define operations kK Filling Foundry comps Strategy Contacts HTC Env Special Output AXN Therman Contacts properties Identifier Comp 1 Comp 2 HTC cond W m 2 K HTC conv W m 2 K Pairl Part Mould 7000 0 3000 0 Figure G 23 Contacts label In the Contacts label Figure G 23 we set the values of the Heat Transfer Coefficients HTC for the contact between the casting and the mould This contact is characterized by two different values HTC conduction and HTC convection Change values to HTC conduction 2000 HTC convection 1000 And continue to the next label GET STARTED TUTORIAL HPDC G 41 Define operations UTE Foundry comps Strategy Contacts HTC Env Special Output WA Therman HTC environment properties Identifier Foundry component HTC environment Part Env Part HTC Aluminium Mould Env Mould HTC Gray lron Add Modify HTC environment curve Component HT
139. tation First point is a surface Therefore from the Mum 0 0 menu Entities Type choose goo Surfaces a z 0 0 W Two dimensions 3 Enter 3 in the Angle box and click Second point a checkmark into the box preceding Num 0 0 Two dimensions Provided we y 0 0 define positive rotation in the gt z 00 mathematical sense which is counterclockwise 3 degrees will mean a clockwise rotation of 3 degrees 4 Enter the point 0 0 0 under First a Le esl ce Point This is the point that defines Do extrude Surfaces v the center of rotation 5 Click Select to select the surface that is to rotate which in this case is that of the circle Multiple copies 1 W Maintain layers 6 Press ESC or Finish in the Move Select Cancel window to indicate that the selection of surfaces to rotate has been made thus executing the rotation Figure 5 The Move window B 8 VULCAN TUTORIALS 2 5 Rotating the circle 36 degrees around a point and copying it 1 Use the Copy window located in Utilities gt Copy 2 Repeat the rotation process explained in section 2 4 but this time with an angle of 36 degrees See Figure 6 Figure 6 Result of the rotations Ja NOTE The Move and Copy windows differ only in that Copy creates new entities but Move only displaces entities already selected VULCAN TUTORIALS 2 6 Rotating and copying the auxiliary lines 1 Use the Copy window located in Utilities Copy See Figure
140. te a line between point 55 0 and the point generated by the intersection To select the points use the option Join C a in the tool Line Choose the option Geometry gt Edit gt Intersection gt Lines to make another intersection between the lower circle and the line segment between point 40 0 and point 55 0 See Figure 12 Again go to the option Geometry gt Edit gt Intersection Lines to make an intersection between the upper circle and the farthest segment of the line that was rotated 36 degrees See Figure 12 VULCAN TUTORIALS Figure 10 The two lines selected d Figure 11 Intersecting lines Figure 12 Intersecting lines Ja NOTE The order of selection in the intersecting process is important since the second line selected can not have higher entities VULCAN TUTORIALS B 11 2 8 Creating and arc tangential to two lines 1 Choose Geometry Create Arc By3points or go to the VULCAN Toolbox 2 Open the mouse menu and go to Contextual click By Tangents Enter a radius of 1 35 on the command line see footnote 2 on page 4 Figure 13 The line segments to be selected 3 And select the two line segments shown in Figure 13 Then press ESC to indicate that the process of creating the arcs is finished 2 9 Translating the definitive lines to the profile layer 1 Ifthe profile layer is not already selected doubleclick on it to select it 2 Select the profile layer in the Laye
141. temperature on the chillers cores etc Go to Vulcan results Temperature evolution or select the button ___GETSTARTEDTUTORIAL HPDC o G9 The result will be like this TEMPERATURES 282 28 277 09 271 89 266 69 261 49 296 29 251 1 245 9 240 7 235 5 Figure G 49 Temperature evolution In this result we can animate and see the temperature evolution in the casting surface but it would be interesting to cut the casting and see the temperature inside To do so we will make a cut of the casting and mould Go to Vulcan results Results evolution with graphs or select the button Select Cut xz plane button and then draw a line dividing the mould horizontally in two equal halves Selecting the Show cut sections the result will be G 60 GET STARTED TUTORIAL HPDC Graph options Cut plane Show cut sections Point evolution Toogle mesh graph view Clear graphs Graph manager Figure G 42 Temperature in cut On the figure we can see the temperature evolution of both the casting and the mould in the Cut xz plane By pressing the Play button on the animate window we can see all the temperature evolution during solidification select render normal to see a better resolution ___GETSTARTEDTUTORIAL HPDG o Gw Now we will add a virtual thermocouple in a point in the middle of the casting Go to ca View results Graphs P
142. ten metal fills the entire mould At this moment solidification starts as metal begins to cool down and solidify solidification finishes when the last part of the casting turns into solid phase At this moment cooling starts and goes all the way down until the casting and mould reaches room temperature In our gravity casting example we are going to run a simulation the filling and solidification parts of the process Click on the add operations J icon The following window will appear fF Add anew operation ES Name Filling Select operation type f Cycling Filling Thermmo Mechanical solidification fo C Thermal solidification m Mechanical Ok Cancel Here we have to select all the operations we want to simulate one by one Leave Filling and click OK and then enter on the same previous icon and select Thermal solidification operation GET STARTED TUTORIAL GRAVITY CASTING The result should look like this Define operations S Filing Foundry comps Strategy Contacts HTC Eny Special Output N Thermal Available foundry components Selected foundry components Mould Part Figure F 238 Operations definition In Figure F 23 we can see that all the foundry components are assigned by default to the filling and solidification operations In Figure F 18 we created those foundry components Here we have the option of changing the foundry components selecting differe
143. tep when the Play button is pushed Here the filename given will be used as a prefix to create the TIFF JPEG GIFs for instance if you write MyAnimation TIFF JPEG GIF files will be created with names MyAnimation 01 tif MyAnimation 01 gif MyAnimation 02 tif MyAnimation 02 gif and so on Save MPEG Avi mjpeg AVI MS Video 1 AVI raw True Color AVI raw 15 bpp VD AVI raw 16 bpp MS GIF on Entering a filename here a MPEG AVI GIF file will be created when Play button is pushed Then we have the animation controls HOE these controls are the standard Play Pause Stop Fast Forward Rewind controls We can control the evolution of the animation with them GET STARTED TUTORIAL GRAVITY CASTING Let s say now that we want to see other phenomena for example turbulences formation highest filling velocities inside the casting velocities at which the advancing fronts encounter etc We will use a different representation to see these results Go to Vulcan results Filling vectors or press the button And again the animate window will show up The animation will show the velocity vectors inside the casting Figure F 40 Filling vectors animation The colour scale represents the module of velocity In Figure F 40 we can see the highest velocities in red and the lowest velocities in blue Once finished with filling vectors go to View results No results GET STARTED TUTORIAL GRAVITY CASTING Now we want to see
144. ting the last line created 120 degrees In the Copy window choose Translation from the Transformation menu and Lines from the Entities Type menu The translation vector for the translation to be made is the line just created As the first point of the translation select the point farthest from this line segment For the second point select the other point of the line Figure 5 First point Figure 2 The line segment selected is the Figure 6 Result of the translation translation vector with copy Click Select to select the line segment that forms an angle of 60 degrees with the horizontal Press ESC to indicate that the selection has been made Choose Geometry gt Edit gt Intersection gt Lines Select the two inner lines The intersection between the two entities lines creates a point This point will be the tangential center VULCAN TUTORIALS C 7 Figure 3 The auxiliary lines Ja NOTE The option Undo enables the user to undo the operations most recently carried out If an error is made go to Utilities gt Undo a window comes up in which to select all the options to be eliminated C 8 VULCAN TUTORIALS 3 CREATING THE FIRST COMPONENT PART In this section the entire model except the T junction will be created The model to be created is composed of two pipes forming a 60 degree angle To start with the first pipe will be created This pipe will then be rotated to create the second pipe 3 1 Creating the profile
145. under study but sometimes too many details in the part leads to element distortion or a to a very high number of elements which will increase the calculation time Vulcan is a software that has the tools for geometry preparation but the dedicated CAD system in which the part has been designed is usually well known by the user and a few geometry preparation steps previously done in the CAD system will help to export the files and will make the meshing easier so the preparation should start in the dedicated CAD system this way will be faster and will drastically reduce preparation in Vulcan In this tutorial we will show some procedures that can be done in the CAD system used before exporting the part into Vulcan and this way avoiding distortions and saving calculation time We will see a mesh without corrections and then a mesh previously corrected before importing into Vulcan in order to study the differences and understand why it is convenient to simplify some aspects of the geometry under study GET STARTED TUTORIAL GEOMETRY CORRECTION EXPORTING A GEOMETRY DESIGNED IN A CAD ENVIRONMENT In this tutorial we are going to generate a Finite Element mesh in Vulcan out of a geometry made in a parametrical CAD environment we will mesh the following part generated in CATIA V5 Figure D 1 Part made with CATIA V5 Part Design module Tg NOTE CATIA and CATIA V5 are registered trademarks of Dassault Systemes GET STARTED TU
146. volumes created the mesh may be generated First we will generate a simple mesh by default Depending on the form of the entity to mesh VULCAN makes an automatic correction of the element size This correction option which by default is activated maybe modified from the Preferences window in Meshing under the name of Automatic correct sizes Automatic correction is sometimes not sufficient In such cases the user must indicate where a more precise mesh is needed Thus in this example we will increase the concentration of elements along the profile of the wheel by following two methods 1 assigning element sizes around points and 2 assigning element sizes around lines 5 1 Generating the mesh by default 1 Choose Mesh Generate Mesh 2 A window comes up in which to enter the maximum element size of the mesh to be generated Figure 32 Leave the default value given by VULCAN unaltered and click OK B 22 UL AN TUTORIALS Mesh generation Get meshing parameters from model Figure 32 The window in which to enter the maximum element size 3 A window appears that shows the meshing progression Once the process is finished another window comes up with information about the mesh that has been generated Figure 33 Click View mesh to visualize the resulting mesh Figure 34 Dialog window O Mesh generated Num of Tetrahedra elements 39986 Num of nodes 8662 Figure 33 The window with information Figure 34 T
147. w and layer to use is the layer used to create delete or modify geometry 11 GET STARTED TUTORIAL LPDC e Select the layer Layer1 enter the name mould in the textbox by clicking on Rename button e Be sure that Layer to use is cast it says so beside the button and there is a checkmark v in the layer name e Select the layer mould and click on Send To button and then Surfaces e Go to the casting geometry and select the six surfaces that form the exterior of the mould e Turn off the layer mould e Select the layer cast and then Send To and select all the cast surfaces then press Esc e Close the layers window The resulting geometry at this moment shall look like Figure H 8 Figure H 8 Gravity casting geometry 12 GET STARTED TUTORIAL LPDC The geometrical entities in Vulcan have the following hierarchy order Points Lines Surfaces Volumes We can interpret the hierarchy by higher entities and lower entities For example a surface is higher than a line a surface is lower than a volume etc we cannot delete a surface if there are related higher entities present Volumes In Figure H 8 we can see the points in black lines in blue and surfaces in pink There are always points that define line ends lines that define surfaces etc Now that we have a geometry to work with let s begin with the next step geometry treatment 13 GET STARTED TUTORIAL LPDC Step 2 GEOMETRY TREATM
148. y the lines would appear under a different colour and labelled Boundary or Isolated lines The lines at the entrance of the material Other are connected to more than two surfaces because they are also connected to the mould surfaces so they have a different colour this is correct The other lines are all interior in red This means that all the lines are connected to two surfaces the lines are not forming open boundaries or are isolated lines In other words this geometry consisting of points lines and surfaces is sound We can rotate and zoom the casting while we are in draw higher mode Now let s press Esc to go back to the geometry We have now a repaired geometry Lets move on to the next step ___GETSTARTEDTUTORIAL HPDC oo y y OGay Step 3 MESH GENERATION Before start the meshing generation we will set the Meshing parameters as shown in Figure G 5 Go to Utilities Preferences and select the label Meshing Set all the parameters as shown in the figure Preferences General Graphical Meshing Exchange Fonts Format Grid Quadratic type Normal Quadratic Quadratic9 Unstructured mesher Surface RFast RSurf Volume Advancing front Delaunay Isosurface Automatic correct sizes None Normal Hard Unstructured size transitions v Regular transition near boundary Chordal error Maximum chordal error in model relative 0 0

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