procast相關(guān)高級(jí)培訓(xùn)

1Copyright?ESIGroup,2006.Allrightsreserved.ProCAST高級(jí)培訓(xùn)ESI國際工程科學(xué)（中國）有限公司2Copyright?ESIGroup,2006.Allrightsreserved.目錄MeshCAST——網(wǎng)格裝配、布爾運(yùn)算正確設(shè)置Velocity邊界條件軟件使用技巧3Copyright?ESIGroup,2006.Allrightsreserved.重力鑄造對(duì)于砂型鑄造沒有限制，要獲得較平穩(wěn)的水平液面，設(shè)置參數(shù)：FREESFBAL=2(tobeaddedmanuallyinthep.datfile)

ThiscanbeusedinGravitycasting(andonlyinGravitycasting)whenyouhaveanimportanthorizontalfreesurface.Sometimes,thefreesurfaceisgettingquiteagitated.FREESFBAL=2iscalmingdownthisfreesurfacewhichcorrespondsmuchmoretothereality.Inthecode,itcorrespondtoamoreaccuratetreatmentofthemassbalanceatthefreesurface,whichremovesthekindofinstabilitythatweobservedinlargehorizontalfreesurfaces.4Copyright?ESIGroup,2006.Allrightsreserved.傾轉(zhuǎn)澆注需要在p.dat中添加一下參數(shù)以獲得更好的結(jié)果：TILT1DETACHTOP1FREESFBAL25Copyright?ESIGroup,2006.Allrightsreserved.球鐵／灰鐵砂型鑄造參數(shù)推薦值：MOLDRIG(0.5)GRAPHITE(0.4-0.6)MGTREAT:(孕育時(shí)間)6Copyright?ESIGroup,2006.Allrightsreserved.CAFECellsize一般選擇１００微米(50~200)（約等于SDAS）Block一般選擇１０Ｘ１０Ｘ１０(10,000,000個(gè)cell)Ａ356的參數(shù)如下：LiquidTemp:616GrowthKinetics計(jì)算參數(shù)：616102e-710Si7-60.1173e-9VolumeNuleation:DTm6DTs1Nmax1e9~107Copyright?ESIGroup,2006.Allrightsreserved.CAFéSurfaceNuleationGaussianDTm4DTs1GMax1e6~7Growangle2D0~453D0~548Copyright?ESIGroup,2006.Allrightsreserved.InletBoundaryconditionEnoughflowrateToavoiddiffusionproblemsToconcentratefallstream9Copyright?ESIGroup,2006.Allrightsreserved.Tips&Traps–Inletvelocity

Typicaldistanceofthecrucible:10-20cm

Setaninletvelocitybetween1m/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–Materialpropertiesmendedcoolingratesforbackdiffusioncalculation: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–CADAssembly

WrongcoordinatesystemreferenceinMeshCASTforCADassemblies!17Copyright?ESIGroup,2006.Allrightsreserved.Tips&Traps–CADAssembly

SaveasaPart18Copyright?ESIGroup,2006.Allrightsreserved.Importtopro-cast對(duì)于更改工藝，或主體相同只有很少細(xì)節(jié)不同的鑄件計(jì)算，使用import/exportgeom命令在前期進(jìn)行裝配，可以大大減少工作量。將新澆鑄系統(tǒng)保存為單獨(dú)的gmrst文件。19Copyright?ESIGroup,2006.Allrightsreserved.Importtopro-cast將原鑄件通過import命令導(dǎo)入當(dāng)前文件中，如圖所示，導(dǎo)入的鑄件和鑄件位置完全吻合。20Copyright?ESIGroup,2006.Allrightsreserved.Importtopro-cast將重合面上的線加入所在公共面，完成合并。21Copyright?ESIGroup,2006.Allrightsreserved.ClicktoeditMastertitlestyle1、使用checkintersections按鈕檢查，可能存在的交叉網(wǎng)格2、在inputwindow中輸入結(jié)點(diǎn)序號(hào)，使用deleteconn按鈕刪除與該點(diǎn)相連的單元。22Copyright?ESIGroup,2006.Allrightsreserved.3、點(diǎn)擊inactivenodes按鈕，選擇要縫合crack的結(jié)點(diǎn)序號(hào)，并輸入到inputwindow中，點(diǎn)擊connectcrack按鈕，完成自動(dòng)縫合。23Copyright?ESIGroup,2006.Allrightsreserved.24Copyright?ESIGroup,2006.Allrightsreserved.ClicktoeditMastertitlestyle有兩種方式：半自動(dòng)，指定起始溫度及增量；指定溫度。常用指定溫度方法：設(shè)定固相溫度，得到各部分達(dá)到固相溫度所用時(shí)間。25Copyright?ESIGroup,2006.Allrightsreserved.輸入溫度值，設(shè)置單位。點(diǎn)擊apply進(jìn)行計(jì)算。26Copyright?ESIGroup,2006.Allrightsreserved.計(jì)算結(jié)束后，得到Isochrons選項(xiàng)。27Copyright?ESIGroup,2006.Allrightsreserved.顯示各部分達(dá)到固相線溫度1664所用的時(shí)間。28Copyright?ESIGroup,2006.Allrightsreserved.通過cutoff選項(xiàng)，顯示達(dá)到凝固溫度時(shí)間較長的區(qū)域。應(yīng)該與孤立液相區(qū)一直。29Copyright