ProCAST_高级培训

1Copyright©ESIGroup,2006.Allrightsreserved.ProCAST高级培训ESI国际工程科学（中国）有限公司2Copyright©ESIGroup,2006.Allrightsreserved.目录MeshCAST——网格装配、布尔运算正确设置Velocity边界条件软件使用技巧3Copyright©ESIGroup,2006.Allrightsreserved.重力铸造对于砂型铸造没有限制，要获得较平稳的水平液面，设置参数：FREESFBAL=2(tobeaddedmanuallyinthep.datfile)ThiscanbeusedinGravitycasting(andonlyinGravitycasting)whenyouhaveanimportanthorizontalfreesurface.Sometimes,thefreesurfaceisgettingquiteagitated.FREESFBAL=2iscalmingdownthisfreesurfacewhichcorrespondsmuchmoretothereality.Inthecode,itcorrespondtoamoreaccuratetreatmentofthemassbalanceatthefreesurface,whichremovesthekindofinstabilitythatweobservedinlargehorizontalfreesurfaces.4Copyright©ESIGroup,2006.Allrightsreserved.倾转浇注需要在p.dat中添加一下参数以获得更好的结果：TILT1DETACHTOP1FREESFBAL25Copyright©ESIGroup,2006.Allrightsreserved.球铁／灰铁砂型铸造参数推荐值：MOLDRIG(0.5)GRAPHITE(0.4-0.6)MGTREAT:(孕育时间)6Copyright©ESIGroup,2006.Allrightsreserved.CAFECellsize一般选择１００微米(50~200)（约等于SDAS）Block一般选择１０Ｘ１０Ｘ１０(10,000,000个cell)Ａ356的参数如下：LiquidTemp:616GrowthKinetics计算参数：616102e-710Si7-60.1173e-9VolumeNuleation:DTm6DTs1Nmax1e9~107Copyright©ESIGroup,2006.Allrightsreserved.CAFÉSurfaceNuleationGaussianDTm4DTs1GMax1e6~7Growangle2D0~453D0~548Copyright©ESIGroup,2006.Allrightsreserved.InletBoundaryconditionEnoughflowrateToavoiddiffusionproblemsToconcentratefallstreamFreefall0.00000.50001.00001.50002.00002.50003.00003.50004.00004.50005.00000.00000.20000.40000.60000.80001.0000Fallingdistance[m]Fallingvelocity[m/s]9Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–InletvelocityTypicaldistanceofthecrucible:10-20cmSetaninletvelocitybetween1m/sand2m/s(neverbelow1!)Checktheinletatstep0Becarefulaboutmeshsizebelowfallingliquidstream(minimum2-3eltsinthethickness)10Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–MaterialpropertiesMicrosegregationmodels:Scheilmodel:Nodiffusioninthesolid,Highcoolingrates(20K/s)Leverrule:Verygooddiffusioninthesolid,Lowcoolingrates(0.01K/s)Backdiffusion:Limiteddiffusioninthesolid,11Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–MaterialpropertiesRecommendedcoolingratesforbackdiffusioncalculation:CastingInvestmentSandPermanentmoldDiecastingCoolingrate(K/s)1101001000Ifcoolingslowerthan0.01K/suseLeverForIronandCarbonsteeluseLever12Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–MaterialpropertiesMaterialdatanotrealistic?:Suppress(i.e.ignore)theelementspresentinverylowconcentrationsandrelaunchScheil,LeverorBackdiffusionmodelsErasewrongvalues13Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–MaterialpropertiesMaterialdatanotrealistic?:ErasewrongvaluesChecksolidus&liquiduswithFractionofsolidcurve14Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–MaterialpropertiesMaterialdatanotrealistic?:Checktheenthalpy:shouldbemonotonicRunasimplecase(checksolidificationtime,porosityprediction,…)15Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–MaterialpropertiesTypicalcurvesforstressdata16Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–CADAssemblyWrongcoordinatesystemreferenceinMeshCASTforCADassemblies!17Copyright©ESIGroup,2006.Allrightsreserved.Tips&Traps–CADAssemblySaveasaPart18Copyright©ESIGroup,2006.Allrightsreserved.Importtopro-cast对于更改工艺，或主体相同只有很少细节不同的铸件计算，使用import/exportgeom命令在前期进行装配，可以大大减少工作量。将新浇铸系统保存为单独的gmrst文件。19Copyright©ESIGroup,2006.Allrightsreserved.Importtopro-cast将原铸件通过import命令导入当前文件中，如图所示，导入的铸件和铸件位置完全吻合。20Copyright©ESIGroup,2006.Allrightsreserved.Importtopro-cast将重合面上的线加入所在公共面，完成合并。21Copyright©ESIGroup,2006.Allrightsreserved.ClicktoeditMastertitlestyle1、使用checkintersections按钮检查，可能存在的交叉网格2、在inputwindow中输入结点序号，使用deleteconn按钮删除与该点相连的单元。22Copyright©ESIGroup,2006.Allrightsreserved.3、点击inactivenodes按钮，选择要缝合crack的结点序号，并输入到inputwindow中，点击connectcrack按钮，完成自动缝合。23Copyright©ESIGroup,2006.Allrightsreserved.24Copyright©ESIGroup,2006.Allrightsreserved.ClicktoeditMastertitlestyle有两种方式：半自动，指定起始温度及增量；指定温度。常用指定温度方法：设定固相温度，得到各部分达到固相温度所用时间。25Copyright©ESIGroup,2006.Allrightsreserved.输入温度值，设置单位。点击apply进行计算。26Copyright©ESIGroup,2006.Allrightsreserved.计算结束后，得到Isochrons选项。27Copyright©ESIGroup,2006.Allrightsreserved.显示各部分达到固相线温度1664所用的时间。28Copyright©ESIGroup,2006.Allrightsreserved.通过cutoff选项，显示达到凝固温度时间较长的区域。应该与孤立液相区一直。29Copyright©ESIGroup,2006.Allrightsreserved.如何使用niyama准则niyama准则依赖于温度梯度，网格变化会影响结果，目前看来并不是非常准确。当采用默认单位时：cmC色标设置一般为：0--30\45使用切面分析内部的危险点（spot）选择适当的值，设置Cutoff来显示分布情况一般来说procast自带的shrinkageporosity更准确，但通过niyama准则可以更好的分析早期凝固区域中未形成孤立液相区的缺陷。