材料数值模拟基础（朱鸣芳）fdmsoftwares

1、introduction of fdm software1. magmalei brief introductionmagma is the comprehensive and effective simulation tool for improving casting quality, optimizing process conditions and substantially reducing costs in the foundry.magma is designed to predict total casting quality by simulating mold fillin

2、g, solidification and cooling, and, optionally, stresses/strains as well as microstructure formation and property distributions in casting manufacturing processes.1.2 capabilitymagma standard has a modular structure and contains the following functionalities for a comprehensive simulation: a common

3、graphical user interface for all modules a project management perspective for handling of project versions solid modeling of geometries using a cad kernel as well as import and export of cad data automatic meshing of geometries for the simulation comprehensive process mapping with direct access to a

4、ll materials, process steps and the corresponding simulation settings simulation programs for the calculation of mold filling, solidification, cooling and serial casting applications interactive and automatic result evaluation. several perspectives can be opened and edited at the same time module fo

5、r the management of thermophysical and other process-specific data for the simulation1.3 solution sequence1) preprocessing geometric entity modeling cad data interface automatic meshing2) main processing input parameters3) postprocwssing three-dimensional display evaluate result1.4 applications1) ca

6、st iron consideration of the actual melt composition, melt treatment and inoculation utilization of kinetic models and micromodeling throughout the entire process for accurateshrinkage prediction based on the local solidification path and phases formed consideration of mold strength and its impact o

7、n shrinkage defects prediction of local microstructures and mechanical properties for gray, ductile and compacted graphite iron prediction of mold erosion, sand bunvon/penetration and tracking of sand inclusions detailed capabilities and data bases for vertically parted molding residual stresses and

8、 distortions in castings during solidification after shake-out, gate and riser removal during cooling and subsequent processing evaluation of stresses and distortion of the casting during solidification, shake-out, after removal of the gating and risering, as well as during subsequent cooling and ma

9、chining process stress relief and distortion during heat treatment2) steel pouring from ladles with calculation of the ladle characteristics prediction of mold erosion, sand burn-on and penetration calculation of melt convection during solidification and corresponding casting macro segregation quant

10、ification of centerline and macroscopic shrinkage tracking of the development of re-oxidation and sand inclusions, and prediction of bum o n/penetration dedicated capabilities for steel investment casting and shell molds crack prediction, stress and distortion of the casting during solidification sh

11、ake-out, after removal of gating and risering, as well as during subsequent cooling and machining processes evaluation of casting stresses and distortion during heat treatment prediction of local microstructures and mechanical properties during and after heat treatment considering the actual melt co

12、mposition3) die casting filling and pouring from pouring ladles and dosing furnaces filling and cooling in the shot chamber high pressure die casting calculator for the filling of the 1st and 2nd phase, part- and machine-specific consideration of surface tension, venting and vacuum for the shot poro

13、sity prediction also considering the 3rd phase (intensification) local squeezing time- or temperature-controlled heating and cooling circuits warm-up of dies with all thermal and time-related boundary conditions local spraying and blowing residual stresses and distortions in castings during solidifi

14、cation after casting removal, gate and overflow cut off as well as during cooling die stress, prediction of die life and heat checking stresses and distortions in castings due to stamping and heat treatment measurement-based evaluation of part distortion4) non-ferrous comprehensive process mapping o

15、f low pressure die casting, permanent mold casting, tilt casting, rotacaster and roll-over processes in simulation filling and pouring from ladles and automatic pouring furnaces consideration of pressure conditions during filling and solidification for in low pressure die castings consideration of m

16、elt surface tension and fluidity as well as venting calculation of air flow through cores, as well as consideration of vents in sand and permanent molds assessment of porosities, oxide and slag inclusions in-situ process control with time- or temperature-controlled regulation of heating and cooling

17、system, mold open and quenching in the simulation consideration of actual melt composition, melt treatment, grain refinement and hydrogen content and their impact on casting quality prediction of local microstructures and mechanical properties crack prediction, stress and distortion of the casting d

18、uring solidification shake-out, after removal of the gating and risering, as well as during subsequent cooling and machining processes prediction of casting stresses and distortion during quenching and heat treatment consideration of mold stresses including mold life time assessment5) core and mold

19、robust prediction of the shooting behavior of complex cores for organic and inorganic binder systems flexible optimization of nozzles and venting conditions consideration of the shoot head integrated simulation of shooting and curing behavior gassing and purging and curing for coldbox cores layout a

20、nd temperature control for hot core boxes prediction of the curing reaction for hotbox cores with organic and inorganic binder systems1.5 examples1) steelmagma, magmasteel and extension modules such as magmastress provide comprehensive capabilities to simulate the steel casting process realistically

21、 and reliably.fig/1 porosity indication (left) and re-oxidation inclusions (right) in magma2) die casting.with modules like magmahpdc and other task-specific components, magma offers extensive possibilities to simulate die casting processes in a realistic and reliable way.fig.2 simulation of turbule

22、nce formation and resulting gas inclusions with the magmahpdc module3) batteries & fuel cellsmagma, magmalpdc, magma permanent mold and other task-specific modules offer extensive possibilities to simulate nonferrous casting processes in a realistic and reliable way.fig.3 process chart in magma:

23、 example of a non-ferrous casting2. anycasting2.1 brief introductionanycasting is an analysis program designed exclusively for casting process. it help to predict filling and solidification pattern and each of casting defects.anycasting is applicable to all casting processes, including sand mold cas

24、ting, permanent casting, low- and high- pressure die casting, due to its high graphic and calculation speed and accuracy the program predicts, rapidly and accurately, all problems that can potentially develop during casting process.2.2 capabilityconvenient to use: operation possible on a personal co

25、mputer ms windows-based program casting process-oriented structure full three-dimensional graphic support utilizing openglvarious application fields: high pressure die casting low pressure die casting cyclic casting sand casting metal mould casting investment casting tilting casting fluidity simulat

26、ion2.3 solution sequenceanycasting is composed by these modules:1) anypre mesh generation simulation conditions2) anymesh mesh editing without cad modeling3) anysolver fast & accurate prediction for casting process4) anypost powerful visualization & analysis5) anydbase active & structura

27、lized database6) batch-runner manage anysolver projects1. preprocessing meshing set up conditions2. solution analyze all the flows that develop during a casting process, it contains viscosity model, turbulence model as well as the shrinkage and microstructure prediction model3. postprocessing provid

28、e 2d or 3d graphic displays of the results generate reports2.4 applications1) high pressure die casting it is possible to calculate the melt filling and heat distribution inside the sleeve using plunger model based on the results of such calculation. prediction of defective areas following applicati

29、ons of vacuum optimization of cooling design through heat and solidification analysis evaluation of cooling capacity based on conditions of the cooling hannel analysis of mold temperature distribution due to relative work analysis of optimized cycletime of continuous casting process2) low pressure d

30、ie casting reproducing the situation where the un-solidified melt in the stalk returns to the holding furnace when pressure is added through the gate at the end of filling, a prediction can be made of the time when pressure can be stopped.3) sand casting as ordinary filters were used in the database

31、, the user can apply filter modules easily. it is not necessary to arrange multiple filters along the x, y and z axis but he can analyze the filling pattern by simply setting the filters in any arbitrary direction.4) metal mold casting after the rotatory angle of the mold and the melt conditions of

32、the hopper are set, the pattern of the melt being filled is shown. after the filling, the shrinkage defect due to the effect of the added pressure can also be observed. pouring-basin module can cope with a situation where the liquid is no longer supplied after being filled in the pouring basin or it

33、 can ensure that a steady volume of the liquid is maintained or that the liquid fills the pouring basin flowing from the ladle.5) large ingot casting in the process for casting a large product weighing over 100 tons, ladles must be changed during casting for additional supply of liquid. the time for

34、 analysis is reduced as analysis is converted to solidification between the first injection and the additional supply of melt. in this process, the liquid is re-melted. when casting a large product, segregation of elements takes place along the solid/liquid interface during solidification. such a se

35、gregation may cause a crack as stress is concentrated when molding the product. anycastingtm can predict the segregation of various elements taking into account the convection, natural convection and diffusion of the solute. intefrated quality prediction process construction is composed of casting s

36、imulation and forgingsimulation6) special casting centrifugal casting: set simple conditions such as the rotation axis，the speed of rotation and the direction of rotation. perform flow analysis applying the centrifugal force and inertia. investment casting: this method predicts micro-shrinkage on th

37、rough, feeding efficient method which makes it possible to judge effectiveness of the riser and the runne匚 this, in turn, makes it possible to set up the mold design and casting conditions and decided on an advantageous casting design.2.5 examples1) sand castingfig.4 material: cast steel(scm430)/san

38、d: chromites sand2) shrinkage defect predictionfig.5 shrinkage defect distributionezeeeeeii3) metal mold castingfig.6 filling pattern of cylinder head3 jscast3.1 brief introductionjscast is a casting simulation software released by komatsu software company and osaka university, it is suitable for si

39、mulate all kinds of casting and metal filling and solidification process, it is widely used to shorten the test time and reduce the casting cost, optimize casting process and improve the corporate reputation.3.2 capabilityhigh accuracy & reliability: prediction of miss-runs and gas defects due t

40、o low temperature & high back pressure. prediction of gas porosity. prediction of inclusion entrainment based on initial melt marker tracing technique. prediction of shrinkageon-demand modeling & simulation service: evaluation & optimizing services available for customers casting designs

41、. stl data is necessary for importing solid models applicable for hpdc, gravity casting, investment casting, lpdc, gravity-tilt casting and etc. please contact us for further information.user-friendly with a variety of functions: arbitrary cross-section auto-searching of shrinkage locations via ct-s

42、can function3.3 solution sequencejscast is consisted by basic module and six senior optional modules:basic module: the flow of all kinds of casting process, solidification parsing vertical grids flow stopping consider the filling flow of filter screen sloping casting multiple segment pouring continu

43、ous (cycle) casting quantitative prediction of shrinkage cavity defectssenior optional modules: regular - irregular hybrid grid module the flow of the back pressure parsing consideration module the thermal stress and deformation analysis module the pressure chamber of the liquid metal flow considera

44、tion module the casting deformation module ct - scan and arbitrary section display shrinkage porosity solidification module surface tension flow module riser parsing modulethe typical solution sequence includes:1) preprocessing import 3d-cad file create solid shape from simple geometriesadd and edit

45、 material propertiesmeshing2) solutionset materials and physical property parameters3) postprocessingmold filling:flow patterns: velocity - pressure - temperature - solid fraction with contours, vectors, or markers for any time or fill percentage.fill time: show when elements are filled with casting

46、 liquidmold temperature: show the temperature distributions in the mold, core and chill (non-asting materials)velocity, pressure and temperature plots: plot variables as a function of time at user-specified monitor points. results can be output to csv-formatted data files.fill percentage plots: plot

47、 a fill-percentage curve for each individual casting during multiple product castingsolidification:temperature: show temperature distribution in casting and moldshrinkage and porosity: predict shrinkage and porosity with simple criteria (solidification time, tempgradient, etc.)quantitative predictio

48、n of shrinkage near riser: show shrinkage prediction results, including macro-/micro-shrinkage and formation timetemperature and solidification fraction plots: plot temperature and solidification fraction as functions of time at user-specified monitor pointsanimation of solidification process: creat

49、e an animation showing the solidification process34 applicationscasting process:high pressure casting, low pressure casting sand casting, metal mold castingprecision casting, shell mold casting gravity casting, sloping castingvacuum casting, the differential pressure casting lost foam castingsuitabl

50、e materials:cast iron, cast steel, high manganese steel, stainless steel, high temperature alloy pure metal, aluminum alloy, magnesium alloy, copper alloy, titanium alloy fever materials, insulation materialscold iron, heater, cooling water, cooling airmetal mold and sand mold (raw sand, furan resin

51、 sand), shell (ceramic, gypsum), core3.5 examples1) air entrapment defects predicitionuii.qem:iifig.7 magnesium alloy die casting air entrapment defect prediction and process improvement2) the mold design of the internal cooling jacket(a)(b)(c)fig.8 the mold design of the internal cooling jacket and

52、 the mold surface temperature control: a) the internal cooling jacket; b) mold surface temperature prediction; c) mold surface temperature measurements4. hzcae4.1 brief introductionhzcae is an important tool for analysis and optimization of casting process, it is released by huazhong university of s

53、cience & technology, and improve it in the long-term practice of production continuously. casting filling and solidification process numerical simulation technology is the key to analyze casting process and predict quality, so it helps engineers to optimize casting process. hzcae improve the qua

54、lity of the products, reduce waste, reduce consumption, shorten manufacture cycle and won the foreign orders. these years, many manufacturers has made remarkable economic benefits with the help of hzcae.4.2 capabilityhzcae is known to generate efficacy including: enhance the scientific decision-making and reduce the dependence on experience predi