Getting Started With QC (Shot Simulation)

Getting started
with QuikCAST
(HPDC / Shot)
Engineering Simulation for

Industry
Getting Started with QuikCAST
List of CAD Files
casting.stl
ESI Group Copyright ESI Group, 2008. All rights reserved.
Getting started with QuikCAST

Import CAD Files
Select New option from the File Menu

Import CAD Files (Core)
2
3
Input Study Name

Browse to define
the Study Location
Click OK

Import CAD Files (Core)
Browse and select the

casting_HPDC.STL file
Click Open to load the CAD

file in the model Window

Import CAD Files (Casting)
11
Click OK
Define CAD File Unit System
( casting_HPDC.STL units is MM)
Activate Welding Point Operation
Input Tolerance value (mm)
10
Activate Automatic Fixing

Import CAD Files (Casting)
QuikCAST gives a description of

the encountered problem when
analysing the CAD files
12
Click YES to continue

Import the CAD (Core)
HPDC Al geometry has been successfully

imported

Automatic CAD Inlet Creation
Select Mesh Basic Shapes

Option from the Model Menu

Select By extrusion option
Input Extrusion Distance (Piston Chamber lenght)
10

Switch to Wire&Shaded
display mode to display the
facets
Entity selection must

be set to Facet
Extruded geometry is automaticallydisplayed for
Select Facets located

on the top of the tube
( SHIFT + left
button)
each new selected facet
11

Click Close
The inlet volume has
been succefully created
12
Automatic Volume detection/Material Assignment
In order to detect/assign volume materials

select Domain Manager Option from the
Model Menu
13
1
Activate the Create
Contact surface option
Click Start to Start the Automatic

Volume detection
New Surface Domains

have been automatically
created because the
Create Contact surface
option has been activated
4 Volume domains have

been detected that need
to be renamed and
assigned with material
properties.
2
Click View
Volume to
display the
Volume_001
1
Select Volume_001 (left click)
3
Click Rename
4
Input Volume
Domain Name
Select Alloy Volume

type
Activate
Standard DB
5
8
Select AlSi9Cu3
Material from the
material list
Click Material
4 5 6 7 8
Repeat the steps
to assign names and materials to the other volumes
9
10
Change Volume
Priority order
with the arrows
( Priority order
should be defined
according to the
Filling order)
Click P to Activate Priority order
11
12
Click Remove to delete the surface
domains created during the import and
during the automatic fixing sequence
Switch to Surface Domain panel

3D Grid/FD Mesh Generation
Select 3D Grid/Mesh Generation option from the

Model menu to generate the Grid
22

3D Grid/FD Mesh Generation
Activate Simplify Method
Select all the volumes
Input Mininum Size to fix

global grid cell size (unit is
meter)
Click Apply to generate the

Grid
Click Run to generate the 3D Mesh
23

Define Gravity Direction
Select Gravity Option from the

Process Menu
24

Define Gravity Direction
2
Click OK
Select PositiveZ direction and check

Gravity Direction ( displayed in green) in
the model window
25

Start the Model Set-up
Select Input Data Check from the

Process Menu and a window with all
available boundary conditions will appear
on the left
This window is used to manage all
Boundary Conditions (BC) that will be
applied to the model
26

Set-up the Metal Flow
Select Initial Fluid BC (left click) to set up the initial fluid rate for the filling
Click on Add... (right click) to open the panel definition
27

Set-up the Sand Flow
3
Input 40% and select Initial
Click OK
4
Select Piston and Chamber
Volumes in the Volume list (left
click)
28

Select Piston BC (left click) to

set up the Sand Core Blowing
pressure
Click on Add... (right click) to open the

panel definition
29

Select Mold
Material for
the piston
Material
Select Velocity Calculator Option to

automatically calculate the transition from
phase 1 to phase 2.i
Input Direction, Max Displacement

and Velocity for phase 1 and 2
Select Inlet/Pressure1
surface domain
Click OK
30

Set-up the Wall Flow laws
Select Temperature BC ( left

click) to set up the metal
injection temperature
Click on Add... (right click)

to open the panel definition
31

Select Initial Option
4
5
Input Alloy Material Temperature
Select Filling Option
Select Chamber
and piston
volume domains
Click OK
32

Set-up the Virtual Mold
Select Implicit Mold BC ( left

click) to set up the Virtual
Mold Material

33

Select Die Material from the Standard

DB list
5
6
Input Average Mold Thickness
Select the Surface domains having

an interface with the die
Click OK
34

Set-up the Wall Heat Transfert
Select Die Coating BC ( left

click) to set up the Virtual
Mold Material

35

Input Average Coating

Thickness
Select Coating Material from the

Standard DB list
Select the Surface domains where

the coating is applied
Click OK
36

Set-up the Output Solver Parameters
Select Output Parameter Option

from the Calculation Menu
37

Set-Up the Output Solver Parameters
Activate the Filling Panel
4
Select by Percent (%) and input a
value in the Graphics field. ( This
will determine the number of states
generated during the calculation
Click Close
Select the Variable

Contours needed for
post-processing
38
Run the Calculation
Select Calculation Start Option from

the Calculation Menu
39
Run the Calculation
Activate Standard Calculation Option

from the Filling/Solidification Panel
Enter Filling and Solidification

Stop Criterias ( Time and/or
Percentage of Filling/Solidification)
Activate High Pressure option
Click RUN to start the

calculation
This will open automatically
the
Monitor Calculation Window
40
Run the Calculation
> Calculation is running now
41

Post-Processing (Visual-CAST)
Select Open option from the File Menu
42

Post-Processing (Visual-CAST)
Select *.MCO file in the study directory
2
Click Open
43

Post-Processing Metal Flow (Visual-CAST)
1
Select Volumes to
load
Click OK
44

Select Snapshot Option from the

Results menu
45

Select THERMAL in Categories and Temperature in

Results to display the temperature results during filling
If your calculation is still running, click Update to update

the last calculated results
Select Arrows to display the differents states
46
Post-Processing Sand Flow Particules (Visual-CAST)
47

Post-Processing Examples (Visual-CAST)
48

Post-Processing Examples (Visual-CAST)
49
Getting started
with QuikCAST
(HPDC Shot)
Engineering Simulation for

Industry

Getting Started With QC (Shot Simulation)

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Getting started

Engineering Simulation for

Getting Started with QuikCAST

List of CAD Files

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Select New option from the File Menu

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Input Study Name

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Browse and select the

Click Open to load the CAD

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Define CAD File Unit System

( casting_HPDC.STL units is MM)

Activate Welding Point Operation

Input Tolerance value (mm)

Activate Automatic Fixing

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

QuikCAST gives a description of

Click YES to continue

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

HPDC Al geometry has been successfully

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Select Mesh Basic Shapes

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Select By extrusion option

Input Extrusion Distance (Piston Chamber lenght)

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Entity selection must

Extruded geometry is automaticallydisplayed for

Select Facets located

each new selected facet

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

In order to detect/assign volume materials

ESI Group Copyright ESI Group, 2008. All rights reserved.

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Click Start to Start the Automatic

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

New Surface Domains

4 Volume domains have

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Getting started with QuikCAST

Automatic Volume detection/Material Assignment

Select Alloy Volume

Getting started with QuikCAST

Automatic Volume detection/Material Assignment