We are using CAE softwsare JS-CAST from Quorica Inc. for cating engineering.
The following is example.
machine desighn/Thermal design
gate design/cooling design
mold cooling design
better cating product quority
Low pressure casting
As shown in the figure,JS-CAST filling analysis adn solidification analysis functions can be used not only for product casting conditions but also for mold, core , stalk, holding furnace. etc..
performing layer flow limit flow speed analysis using ADSTEFAN on the gate
program analysis from JSCAST above, a new casting pressure idea for casting
large wheels was created, and it was possible to find casting conditions that
provided good productivity using 1 gate.
Large motor rotor
Example of using JSCAST's high-speed calculations for performing analysis
of combinations of several conditions and performing optimization analysis
of directional solidification.For large cast products, the solidification
conditions and filling conditions are near the limit values for low-pressure
aluminum casting; therefore, such products require extremely precise control
of casting conditions.Product is used for rotor of large motors.
Cylinder head of side gate
area of the cylinder head has a high defect ratio. The feeder head effect from
the gate is interrupted, and areas of solidification blockage can be seen。
be seen that the valve guide boss section also has areas where there is a high
possibility that shrinkage porosity will be generated
- Countermeasures against defects
1.A temperature gradient between the gate side and the
side opposite the gate is provided for the purpose of directional solidification
Before adding cooling Cooling added
Main runner temp 540 c ---------------------- 650 c
2.Shape is modified to provide feeder head.
Before adding rib ---------------------- Rib added
Before increasing gate height --------Gate height increased
By adding cooling, maintaining runner temperature, adn increasing gate
height, it is clear that the defects will be improved.
When molten metal flows from the gate to the runners, the phenomenon that
the leading edge of the molten metal dips slightly due to the heat quantity
of the runner section, so that the flow of molten metal is not smooth.By maintaining the runner temperature, this phenomenon was improved.
Based on the analysis trends, the following countermeasures were determined for
the cylinder head side gate program:
1. Increase cooling on the side opposite the gate to increase the temperature
gradient, and use a casting removal pin or similar object for increased
2. Since the feeder head effect from the gate is blocked in the runner section,
maintain the temperature using runner sleeves, burners, etc.
3. Create a feeder head path by increasing the side gate height to the middle
As shown in the figure at left, the inclined casting filling analysis function
of JSCAST was used to perform filling analysis in the molten-metal supply
funnel and within the form and set the inclined speed on the inclined-type
casting machine according to the results, and molten-metal behavior analysis
for inside the funnel was performed to determine the inclusion of oxides
and molten-metal supply method. In addition, the feeder head program for
the form was determined by solidification analysis, and the cooling speed
display function was used, DAS2 distribution was predicted.
Diesel engine cylinder head
By using the cooling speed display function of JSCAST, the DAS2 distribution
resulting from the cooling speed at the 577° point after a-phase precipitation
satisfied the material specifications submitted by the automobile manufacturer.
Quenching after solution
We use the thermal conduction analysis function of JSCAST and perform thermal
analysis at the time of quenching after the aluminum solution.
Manufacturing mold and casting trials
We can supply mold manufacturing and casting trials.