Casting Defects

Manufacturing Simulation for the
Casting Industry
with STAR-Cast
Agenda
Manufacturing Simulation
Casting
STAR-Cast
Application coverage
Outlook
Simulation for Manufacturing
Simulation widely used for

E-Coating
Research
Product Design
Verification
Fixed Bed
Thermal
Efficiency
Safety
Increased interest in manufacturing processes

Process simulation
Tool Design
Blast
Furnace
Casting
Manufacturing of Castings
Aspects of Casting Manufacturing

Materials
Casting Processes
Manufacturing:
Non Ferrous alloys

Aluminum
Nickel
Titanium

Ferrous alloys
Steel
Ductile/Grey Iron
.
Die Casting
Tilt
Low/High PressureCasting
Gravity
Precision Casting
Centrifugal
Bridgeman
Continuous Casting
Sand Casting
Casting
Filling and Solidification
Defect distribution
Structural integrity
Accuracy
Tools
Cooling
Design
Longlevity
Overall goal: Increase the quality of the casting and minimize production costs
Casting Simulations
Sensitivity
analyses for
process
parameters
Defect
Elimination
Objectives
where Casting
Simulation
aids
manufacturing
Reduce
number of trial
runs
Geometrical
parameter
studies
Enhancement
and
conservation
of raw
materials
Strategic Partnership
Best of both worlds
Provide state of the art of casting simulation solution by combining the
engineering experience of two companies which have a long-standing
track record in providing CAE solutions and casting processes for over
25 years
Established casting solution STAR-Cast
STAR - Cast
Dedicated tool for Casting Simulations
Key Features:
Multiphase Filling & Solidification
Criteria Functions for Defect Prediction
Material Database
Shell mold generation
STAR-Cast
Latest release (with STAR-CCM+ v8.02) as an Add- on to STARCCM+

From CAD to Post Processing in one GUI
Add all the benefits of having STAR-CCM+ in the background
Expand STAR-Casts application coverage
State of the art Meshing and Solver technology
Parts Based Meshing
Leverage STAR-CCM+s streamlined workflow
New Release of STAR-Cast every 4 months
STAR- Cast: Multi Phase Simulation

Fully Transient Simulation
Simultaneous solving for flow and energy:
Multiphase: Volume of Fluid (VOF)
Resolution of the molten flow and filling front
Model phase change
Conjugate Heat Transfer

Convection, Conduction, Radiation
Across multiple fluids and solids
STAR-Cast : Material Database
A dedicated Material Database is available in STAR-Cast, pooling

all relevant material information for the casting engineer
STAR-Cast: Melting and Solidification
Enthalpy Melting Solidification Model

Enthalpy formulation to track solid portion of the metal phase
Mushy / Slurry Zone for metal alloys

Large solidification intervals
Growing net of dendrites impede flow
Flow Stop Model

Complete stop of flow in solidified areas
Solid
fL= 0.0
Mushy
fL= 0.3
Liquid
fL= 1.0
STAR-Cast: Defect Prediction
Aim is to provide additional information on

the quality and structure of the casting
Shrinkage
Macro/ Micro Porosities
Primary/Secondary Dendrite Arm Spacing
Available Models
Criteria Functions
Macro Porosity Model
centre line porosity
Ref: Access, STAR-Cast
Casting Processes
Die Casting
Low/ High Pressure
Die Casting
Tilt Die Casting
Gravity Die Casting
Sand Casting
Investment
Casting
Other
Processes
Gravity Casting
Centrifugal Casting
Bridgeman Process
Continuous Casting
Composite Casting
Pouring Simulation
STAR-Cast application range
Die Casting Tilt Casting
Tilting of the entire system

Die, Cast Part, Cores,
Tilting curve applied via Rigid Body Motion
Track air bubbles
90 deg turn in 10 s
Die Casting - LPDC

Time depended pressure profile
pushes the melt into the die
Improper process parameters like
pressure profile or die temperature
leads to porosities
Several casting cycles necessary to

achieve steady state temperature profile
Sand Casting
Large and complex castings
Porous mold
Porosity is crucial for the mold filling
Incorporate feeder, cooling irons, filters

Mold filling important for the overall
quality of the casting
Accurately capture the pouring of the
melt
Investment Casting
Challenges in Investment Casting

Thin-walled components with designs at the limit of producibility
New materials
Shell molds/ wrappings
Shell Mold Generator
Courtesy of Access
Automatic shell mold generation
Investment Casting
Lost mold process

Investment mold is porous
Back pressure influences filling
Bridgeman process
Estimate proper heater location and power
Part removal via Rigid Body Motion
Gravity
Centrifugal
Rotating crucible
Stationary crucible
STAR-Cast and beyond
Bringing STAR-Cast and STAR-CCM+ closer together leads to

synergy effects
Extended application coverage
Optimization with OPTIMATE
Detailed Die Cooling analysis
Pouring Optimization
STAR-Cast and OTPIMATE

Leverage STAR-Casts capability with
OPTIMATE for design optimization
Example
Design exploration with STAR-Cast and
OPTIMATE/Sherpa
Find sensitivities between Shape/ Die
temperatures and feeding capabilities
Solidification Front
Feeder
Solidification time ( max)

Solidification front (minimum area)
DIE
DesignParameters
Pouring Optimization with STAR-Cast
Pouring optimization
Reduce misruns
Increase yield
Skull reduction
Use STAR-Cast ( VOF + Overset mesh) to find optimized pouring curve

Variation in rotational speed, pouring height and position
Before optimization
After optimization
Outlook
The new Casting User Interface in v8.04
To be used as a stand alone or parallel to the
simulation tree
Benefits
High degree of automation
Short learning curve
Driven by the casting process
Add additional physics as required
THANK YOU!!
We invite to visit out best practice session on Wednesday from

10:30 to 12:30 in the Royal Palm Ballroom 2
Live Demos to highlight key features of casting simulations with
STAR-Cast
Sneak a peek at the new Casting User Interface
Manufacturing Simulation for the

Casting Industry
with STAR-Cast

Casting Defects

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Casting Defects

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What are some casting processes discussed?

What are some casting processes discussed?

What simulation capabilities does STAR-Cast provide?

What simulation capabilities does STAR-Cast provide?

Manufacturing Simulation for the

Simulation for Manufacturing

Simulation widely used for

Increased interest in manufacturing processes

Aspects of Casting Manufacturing

Non Ferrous alloys

Established casting solution STAR-Cast

Latest release (with STAR-CCM+ v8.02) as an Add- on to STARCCM+

Leverage STAR-CCM+s streamlined workflow

New Release of STAR-Cast every 4 months

STAR- Cast: Multi Phase Simulation

Conjugate Heat Transfer

STAR-Cast : Material Database

A dedicated Material Database is available in STAR-Cast, pooling

STAR-Cast: Melting and Solidification

Enthalpy Melting Solidification Model

Mushy / Slurry Zone for metal alloys

Flow Stop Model

STAR-Cast: Defect Prediction

Aim is to provide additional information on

centre line porosity

Ref: Access, STAR-Cast

STAR-Cast application range

Die Casting Tilt Casting

Tilting of the entire system

Die Casting - LPDC

Several casting cycles necessary to

Incorporate feeder, cooling irons, filters

Challenges in Investment Casting

Automatic shell mold generation

Lost mold process

STAR-Cast and beyond

Bringing STAR-Cast and STAR-CCM+ closer together leads to

STAR-Cast and OTPIMATE

Solidification time ( max)

Pouring Optimization with STAR-Cast

Use STAR-Cast ( VOF + Overset mesh) to find optimized pouring curve

We invite to visit out best practice session on Wednesday from

Manufacturing Simulation for the

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