LPDC Cycling

ProCAST
LPDC - cycling
1
Cycling modelling
Die casting is based upon successive filling and solidification cycles of the component. During the first cycles the mold temperature is reaching a steady
state regime. An optimal temperature distribution of the mold needs to be reached together with the effect of cooling/heating channels in order to ensure
sound castings.
The simulation of the lpdc cycles allows

the determination and optimization of the number of cycles in order to reach the steady state regime
the prediction of the filling behavior using a mold temperature distribution obtained after several cycles
the prediction of the stress formation using a mold temperature distribution obtained after several cycles
the optimization of the position and temperature of the heating/cooling channels
Usually:
1.) Thermal analysis during cycling
2.) Extract the temperature distribution of the die

in the stationnary regime
3.) Fluid flow or stress analysis
2
Interfaces
Interface heat transfer coeff.
fixed part mobile part
Filling and Cooling Spraying

solidification sequence sequence
t=t0 sec t=t1 sec t=t2 sec t=t3 sec t=t4 sec t=t5 sec
Start of one Open the mould Extract the Start Stop End
cycle casting spraying spraying
3
Boundary Conditions
Boundary conditions
external temperature
heat transfer coefficient

Filling and Spraying
solidification Cooling sequence sequence
t=t0 sec t=t1 sec t=t2 sec t=t3 sec t=t4 sec t=t5
sec
Start of one Open the mould Extract the Start Stop
cycle casting spraying spraying End
4
Cycling
Interface
condition
Time
spray
air
Boundary
condition
Time
5
DieCombo method
Interface
condition
Time
spray
air
Boundary
condition
Time
6
Extract temperature principle
The initial temperature of each material should be defined in the initial condition menu.
1 The initial temperature will be defined as an Extracted

temperature field coming from the filling calculation.

In order to apply an extracted temperature field, we
should perform a first calculation on the same mesh.
3 Then, one could specify the case, as well as the step to
be considered for the initial conditions. In the case of an
"Extract", the following screen appears.
2
All available material domains are listed in (1). The
6 desired materials are selected in this list and the case
name from which the thermal field must be extracted (2)
7 should be selected with the Browse button (3). The
directory (4) and the prefix should be selected (5). Then,
the timestep (6) should be defined in the field (7).

When the prefix (and the directory) of the desired case is
selected, if one clicks on it in the "prefix" column (2), the
extracted temperatures are shown.
4
7
Extract temperature distribution
Press Browse to enter the

directory name and the file
the step corresponding

to the desired
temperature field
Select the mould material
8
Temperature
Classical & DieCombo method
diecombo
classical method
stored step
time
9
Interface
The first steps are similar to LPDC – filling, other paremeters are as follows:
Create a die combo

interface between the
dies
You need then to enter

the heat transfer
coefficient, the air heat
transfer coefficient and
the spray heat transfer
coefficient.
10
Boundary Conditions
Add a Heat BC for the external surfaces of the die
Select Air_cooling
condition
There is no need for

other BC’s
11
Heat boundary conditions
The following equation shows the three possible contributions to the "Heat" boundary condition
(all the contributions are added, although they may not be all active in the same time or in the
same cases).The first term corresponds to a specified flux. It can be used if a given heat flux was
measured for instance. The second term corresponds to Convective cooling. This is the most
common definition of the cooling of an external face. It is defined by a heat transfer coefficient
with the ambiance and by an external temperature (of the ambiance). The third term is used at
high temperature, when radiation becomes important. In this case, the transfer is proportional to
the Stefan-Bolzmann constant and the emissivity and the difference of the fourth power of the
temperatures (surface temperature and ambiance temperature).
12
Run Parameters
Select pre-defined set for HPDC cycling
13
Run Parameters
Next step is change of Cycles parameters.

1
2 1. Left-click on Cycles
2. Enter how many cycles we want to
calculate.
3. Third step is to describe how each cycle
looks like. (look at the diagram at the
bottom of this slide). It means, we must
know all specific times.
Filling and solidification Cooling sequence Spraying sequence
Start of one cycle Open the mould Extract the casting Start spraying Stop spraying Mold closing End
14
ProCAST
Save and exit PreCAST and run ProCAST
15
ViewCAST
In file manager find right folder and open ViewCAST
16
ViewCAST
Open ViewCAST and set symmetry on in order to display the complete casting
17
ViewCAST
The full casting can be now displayed
18
ViewCAST
The sector mode is better to look at the internal temperature distribution
19
ViewCAST
An interesting display mode is the ‘explode’ mode. This allows one to display all active domains
with a displacement shift.
20
ViewCAST
Double click on the temperature scale in order to modify the temperature scale
21
ViewCAST
In order to set a white background, select in the menu Parameters ->Reverse
Video option
22

LPDC Cycling

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ProCAST

The simulation of the lpdc cycles allows

1.) Thermal analysis during cycling

2.) Extract the temperature distribution of the die

3.) Fluid flow or stress analysis

fixed part mobile part

Filling and Cooling Spraying

heat transfer coefficient

1 The initial temperature will be defined as an Extracted

Press Browse to enter the

the step corresponding

Select the mould material

Create a die combo

You need then to enter

There is no need for

Next step is change of Cycles parameters.

Filling and solidification Cooling sequence Spraying sequence

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