The material presented in this video are some highlights from NADCA’s online webinar - Modeling: Die Casting Modeling Capabilities - presented by Charlie Monroe.
From the November 22, 2017 Newsletter:
In this course capabilities of die casting process modeling will be reviewed from the current NADCA literature. Common modeling approaches and typical results will be discussed. Topics include: What is simulation, the hows of simulation, and more.
From the highlight:
"Once you have a project description and a clear objective for that simulation, the next question is always how detailed do I need to get on those geometries that I need to simulate. The statement at the top basically is saying without the "right" geometry, as produced on the shop floor, you can't expect to get comparable results
I have, let's say, an expected geometry on the top line, and then I have three different options for simulation on the bottom. Everyone may laugh and say the geometry representation on the left is not very good, but if all I'm interested in the solidification time, for instance, perhaps that core doesn't really, or that slide doesn't really take up much of the solidification heat, and so my simplified block is sufficient to give me the overall solidification time, so I know how long the duration is. That would be one option.
Then in the middle section, you can see that I've removed all the draft, and I have included a slide in this case. In that case, maybe the draft didn't influence my results. If I'm not interested in the filling, if I'm only interested in where is the hot spot in this part, that geometry in the center may be sufficient to answer the question.
Then, on the right, I have probably the most faithful representation of that geometry, but again, maybe I'm missing the parting line, or this may give me more inclination about what the fill might be, what is the finished section on the part, but it still might be missing some different pieces. Again, even from this perspective, you can see that with particular forms of the geometry, I can answer questions, but certainly, if I had a question of whether the draft is sufficient, the two cases on the left is not going to be able to answer those problems for me. I have to make sure that I've included the right pieces of the geometry, the drafting, the correct holes if those are actually cast in holes or removed. Those are all questions that need to be answered as you're going through your model.
This is just giving some additional examples of things that could happen. I certainly ran across many of these when I was working with Caterpillar.
When we're asked to, for instance, quote a geometry or think about it, knowing which of those features are the machined features and what additional stock might need to be added if it is a machined feature may be a missing part of the geometry. Certainly, missing features or unanticipated features that are in there can be a problem for getting a realistic answer to the simulation.
The incorrect runner system from what happens on the die versus what happens in our 3D modeling is a problem.
Any lack of venting or thermal lines are all examples of ways we need to reconcile our geometries with the simulation.
In the process of talking to at least one simulation company about their service group, and when you contract service with them, what was the biggest problem that they saw with the simulations and the setups that they were getting, they quoted a number that was fairly high, that it was about 80% of all the problems with non-comparable to simulation results came from the wrong geometry or the wrong mesh that they had.
Again, these are not problems generally. I know I never go into a project where I'm intentionally trying to not simulate the right geometry, but then in the process of ... Normally our simulations are run earlier, and then later we go back, and we have an actual process, going back and validating that what happens in the shop practice versus what happens in our simulation world, it's very important to reconcile so that we can diagnose future problems that we'd end up having.
To purchase access to this course, visit the NADCA Marketplace at www.diecasting.org/store. Purchasing a course through the online education system grants you one year of access to the recording, presentation, support material, and test when applicable.
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