Frequently Asked Questions
Meshing / Translators
Processes
Simulated
Porosity
Solidification
Stress Analysis
Fluid Flow
Post Processing
Training and Support
Version Releases
Demo
Hardware
Recommendations
Meshing/Translators
-Meshing
tool used
Which modeling system do you use? Finite Elements or
Finite Difference?
Our software
is entirely Finite Element (FEM) based. The accuracy of FEM
versus finite difference is undisputed.
Is FEM difficult to use?
Not
anymore. In the past, the biggest knock against using FEM was the
difficulty in creating a suitable mesh. However, we developed an
automatic finite element mesh generator which makes mesh creation just as
easy as if you were using finite difference software.
Our automatic mesh generator works directly from STL files and can create a
mesh of whole mold assemblies at the push of a button.
Don't FEM simulations take more time?
Not at
all. finite element meshes are much less dense than finite difference
meshes need to be. As a result, finite element simulations take less
time, and less computer resources as well. Not only that, as real world
casting parts become larger and more complex, the finite difference method
becomes even less and less practical.
Can you use other meshing software that is available today?
Yes.
Through a PATRAN's neutral file format or IDEA's universal file format
other meshing software can be used with CAPCAST. In the past,
those who have initially used other meshing software that was originally
developed for structure analysis have failed to be able to create a mesh for
HP die casting process. This is due to the complexity of the die
components. By using our superior FEM mesh generator they were
successful in creating a mesh and have continued to use it since.
-Translators
(importing and exporting)
Are there direct translators for Catia, UG, Pro-E, etc?
Our
software works best with STL files. As long as your CAD program can
export STL, everything is fine.
What translator works best with your software?
As
mentioned above, we achieve the best results when using STL file format.
Does your system have the capability of incorporating cooling
lines in the mold model? Can the location of these cooling lines be easily
changed?
Yes, it
works best when the cooling line voids are incorporated into the original CAD
but cooling lines can also be added in later using MESHID or addition in
house CAD work, with guidance from the customer of course.
Is your system a three-dimensional one?
Yes, most
of our users deal with complex part geometries that cannot be approximated by
one or two dimensional modeling. However, through proper placement of
boundary conditions, the analysis of two-dimensional problems is possible
(and in most cases simple).
Does your system consider the analysis of both the part and
mold, or just one of these?
Our system
models the casting, gating cores, water lines, etc. all simultaneously. This
is extremely important to obtain an accurate representation of the casting
process. We never perform solidification analyses without including a coupled
part & mold model. However, we can de-couple the mold from the part when
doing a filling analysis in those cases where the thermal effects are not
important.
Processes
Simulated
-Does the software work for high pressure die cast
applications, both aluminum and magnesium?
Yes.
CAPCAST was written with HPDC in mind, but it is applicable to all
casting processes. In addition to Mg and Al, the software has databases
for Fe, Zn, Stainless Steel, to name a few. CAPCAST has a successful history
with aluminum high pressure die casting simulation. CAPCAST was
selected as the simulation software of choice for the USCAR Structural Cast
Magnesium Development project. EKK is working closely with the other
USCAR project team members in the development of the magnesium high pressure engine
cradle casting. We have extensive experience using our software to
model the following processes: High Pressure Die Cast (with/without vacuum),
Squeeze Cast (Direct & Indirect), Gravity Permanent Mold, and
Semi-Permanent Mold, Low Pressure Processes, Green Sand, Hard Sand, SSM and
Thixomolding, Structural Investment Casting and Centrifugal Casting. At
the current time, we do not have the ability to model directionally
solidified investment casting (i.e. single crystal castings).
-Can your system model a variety of alloys?
Yes,
material properties including the latent heat curve of the solidifying
material are entered into the analysis software. EKK provides its users
with data for the most popular alloys, but the user is not limited to these
materials. This data can vary with time or temperature.
-Can your system model a variety of Mold Materials?
Yes,
material properties of differing mold materials (i.e. permanent mold, sand)
are also entered into the analysis software. This is true for different
materials within the same mold, i.e. inserts, chills, etc.
With whom do you have experience in the Die Cast & Squeeze
Cast processes?
To
name a few. . . .
Die Cast: Gibbs, JL French, Lunt, Metaldyne
Squeeze Cast: Ube Industries, CMI International , GM
SPM & Low pressure: Hayes Lemmerz, Grenville
Does your system have the capability to convert 3D wire frames
to solid models? Are there any other auxiliary hardware/software items which
would need to be purchased in order to perform a thorough analysis (i.e. A
solids modeling package?)
Our mesh
generator does not use solid models to generate a finite element mesh. We use
STL format to import CAD data. Most CAD programs can output STL files.
We use third party software to convert IGES/UG/Catia to STL in our consulting
projects.
Porosity
-Does the software determine
porosity problems and locations?
Yes.
Our porosity prediction software is highly accurate in Al and Fe
applications. It is recommended for Low Pressure, SPM, and Gravity
casting processes. In high pressure die casting, we found the
location of porosity agrees well with our trapped gas analysis. In a
recent USCAR project, a large scale magnesium cradle casting proved that our
trapped gas results showed precisely where porosity would occur. EKK
authored an article in the May 2003 edition of Die Casting Engineer magazine
regarding this topic.
If so, how does the software show you?
There is a
post processing interface included that allows you to see all your
results. You are able to see the distribution of trapped gas in an
animated view.
Is there a separate module for this?
Technically,
yes. Our porosity prediction software is a separate program, but it is
included with our thermal analysis software. As stated above, we
recommend using the trapped gas analysis for porosity predication in the high
pressure die casting process. This trapped gas is part of the standard
CAPCAST fluid flow package.
Solidification
-Cooling
Does the software show results using water, oil and spray?
Yes.
Our post processing software allows you to view cut sections of the
mold to see the cooling line effect on the mold. You can also view
results at different phases of the production cycle to monitor die
temperatures.
Does your system have solidification modeling capability?
Yes, CAPCAST has a three-dimensional heat transfer program with the ability
to incorporate the latent heat released during the casting process.
-Does the software show thermal distortion?
Yes, we have a stress/distortion package as well. Keep reading.
How does it report it?
The program works by importing temperatures from the thermal analysis and
then conducting the thermal stress/distortion analysis. All the results
are viewable on our post processing interface. Animated deformation is
available as well.
Stress
Analysis
Does the software do stress analysis?
Yes.
How does it report this info?
Again, our post processing software that is included with our package with
display results including animated representation.
Does the software help determine the size of steel required or
do you have to input some data and then the software will analyze?
It will not make explicit recommendations for you. However, once the mesh is
created you have a great deal of flexibility in changing the size.
-Die fatigue (Life Prediction)
How does the software do
this?
Die life prediction currently focuses upon peak strain as a predictor of
thermomechanical die degradation. Peak strain is found to give a good
estimate of trouble spots. This model has not been verified at high
temperatures as of yet. We are currently developing the database to
accommodate high temperatures as well.
Does it show you visually?
We show by a contour plot of die life prediction based on peak strain.
Fluid
Flow
How easy is it to set up a
simulation?
It's quite simple really. CapFD flow simulations are setup using easy
to follow graphical interfaces. Once you have a model you only need to
establish a few parameters in the menu interface (alloy type, gravity
direction, etc) and you are ready to go.
Can you model tilt pour castings?
Of course we can. Don't believe me? Click HERE.
Can you simulate venting
and trapped gas?
Yes. Modeling venting allows for a very accurate prediction of
residual trapped gas in the casting. The simulation also allows you to
model in a vacuum effect as well.
With HPDC can you use the simulation to establish proper shot
parameters?
Yes. With out HPDC simulations you have the option of modeling the shot
sleeve explicitly or using an velocity boundary condition at the
biscuit. The software has a pre-simulation calculator that will take
into account the volume of the casting and the dimension of the biscuit and
give you the minimum sleeve fill and shot speed transition points for an
adequate fill. From there, modeling the shot sleeve allows you to see
if your velocity condition
Is your system capable of showing flow/fill patterns in the
mold?
Yes. Not
only that, post processing visualization will allow you to see flow velocity
vectors, temperatures, percent solid fraction, and amount of trapped gas to
name a few options.
Post
/ Pre Processing
What are your pre- &
post-processor capabilities (node generation, element geometry, result
viewing)?
Pre-Processor: CAPCAST's MESHID interface allows you to inspect your
simulation mesh before simulation, and in some cases you can make explicit
alterations to the mesh if is necessary. The screen is a dynamic
display that allows you to rotate and move your model real time, making
visual inspection very easy. MESHID also houses the graphical interface
to set up all your thermal simulations.
Post-Processor: CAPCAST's CAPOST module has many of the same advantages as MESHID.
CAPOST was designed with the casting process in mind, so several features for
post-processing casting analysis results are automated and
stream-lined. The post processor allows you a dynamic view of
your results. It also has the capability to generate animated graphics
files of your results for easy distribution.
What type of output does your system provide for shop floor
use (temperature distributions, flow patterns, etc.)
Our post-processor, CAPOST, can display various types of output. Some of the
more useful (for shop floor use) are mold temperature distribution, cooling
curves, solidification sequence plots (for identifying potential porosity)
and mold filling sequence (for identifying potential areas of air entrapment
and misruns).
CAPOST can also process a variety of other types of output. You can determine
the type that is most useful for your operation. We can help you in
determining the most useful type of results by showing you various examples
of output.
Training
and Support
How long do you feel training should be?
It takes about 3 days to a week to get familiar with the software.
That’s the duration of our introductory training course here at our
office. After that, most users are pretty comfortable using the
software on their own with consistent use. We are committed to support
after the initial training period. You are always welcome to email, call or
visit with concerns or for help at no additional cost. For those who
purchase perpetual license, the annual maintenance and support fee is
required for all years following the first year of purchase.
What knowledge /education level should the person running your
system have?
Currently we have users that do not have a college degree and we have users
that have a Ph.D. We believe it is most beneficial for the beginning
user to have some casting experience and some computer experience. We
have found that it is easier to "teach" computer skills than
foundry/tooling skills.
What are the costs for training at your site and the customer
site?
Training at our office is included in the overall price of the
software. Training at your location would be charged a per day fee plus
our travel expenses. We recommend training at our facility as it enhances the
overall learning experience.
How accessible is your support staff?
We like to work closely with all of our customers. We are a small
company and do very little advertising. Consequently, we rely on 'word
of mouth' references from our customers. We cannot afford to have any
unhappy customers. We are on the phone with our customers on a regular
basis. Our customers are always invited to bring specific problems to
our site for review by our staff. Customers are encouraged to send us
specific problems electronically (FTP,etc.). We enjoy visiting our
customer sites because we can identify specific needs that can be used to
enhance our software.
Version
releases
How many releases per year?
It varies. At our annual user meeting, we give our customers a complete
CD with the latest version of the software. There are also minor
upgrades that happen throughout the year and customers are free to retrieve
those newer versions from our FTP site. We encourage input from or
customers for software enhancements. We are continuously reviewing
those requests and implementing them as time permits.
Demo
of an existing part
Would you do a full flow layout
with overflows as well as doing a stress analysis on a demo part?
We encourage you to give us an existing part that you are familiar with for a
demonstration. We strongly feel that the best way to compare products
is through an actual demonstration of what can be produced from one your
parts. We would require that you send us the casting geometry files (preferably
STL file format) and some casting process parameters. However, we normally
limit this type of exercise to a relatively simple geometry or we will find
it necessary to charge for some of the modeling costs to cover our
expenses.
Would you be willing to provide a "real world"
example in which your system was used to pinpoint and correct/improve
conditions in a die cast process?
We have several examples showing problems that have been solved, particularly
die castings. We also have some squeeze cast examples. Most of
these case studies are examples where the casting company involved with a
particular part has given us permission to use their part as an example.
Is your software 'proven'?
We feel our software has been proven on all major casting processes. In
addition to selling the CAPCAST software, EKK provides a casting industry
consulting service. We regularly match our results with experimental data
including time - temperature cooling curves (in the casting and mold),
thermal camera surface plot data, porosity correlation to sectioned castings
& x-rays, and Secondary Dendritic Arm Spacing measurements.
Hardware
Recommendations
What platforms do your software
currently run on?
Our software is supported in both Linux and Windows operating systems.
However, for optimal use we recommend a dedicated Linux machine.
What is the preferred hardware and operating system platform
for your software?
We recommend the following as top of the line for running our software:
 Processors:
Two AMD Opteron 285 (4x2.6 GHz 64-bit processors) or
better - Intel Xeon multi-core processors
are supported
Memory: 8 GB RAM
Hard Drive: 500
GB SATA
Video Card: NVIDIA Quadro FX 4500 512 MB PCI-E
OS: SUSE LINUX 10.1 / Red Hat Enterprise Linux WS 4
We recommend
the following setup as sufficient for running our software although it is not
ideal for a long term solution:
Processors:
Two Intel Xeon 2.4
GHz
Memory: 2 GB RAM
Hard Drive: 80 GB
IDE
Video Card:
NVIDIA GeForce4 w/64 MB RAM
OS: LINUX
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