Achieve Premium Quality Castings

What’s New in
ESI ProCAST
2023?

Loïc Calba
March 2023
Public

Copyright © ESI Group, 2023. All rights reserved.

Innovation Without Compromise
 Agenda

1 ESI Casting Solution ProCAST

Introduction

2 Sustain Premium Quality Parts

2023.0 Release Content

3 Cast Early Feasibility

Bridge the Gap between Design and Manufacture

4 Partnerships
Industry Collaboration, R&I

5 What’s next ?
Overview & Solution Roadmap

Copyright © ESI Group, 2023. All rights reserved.

 Agenda

1 ESI Casting Solution ProCAST

Introduction

2 Sustain Premium Quality Parts

2023.0 Release Content

3 Cast Early Feasibility

Bridge the Gap between Design and Manufacture

4 Partnerships
Industry Collaboration, R&I

5 What’s next ?
Overview & Solution Roadmap

Copyright © ESI Group, 2023. All rights reserved.

Smart Manufacturing
Fields of Play

Portfolio Industry
Special Manufacturing
Process Validation

Copyright © ESI Group, 2023. All rights reserved.

• Sound Castings
• Realistic physics & material properties
• Accurate defect prediction
• Microstructure, grain structure &
mechanical property prediction

• Dimensional Control OBJECTIVE

• Seamless tracking of stress history & Help our customers to deliver
hence final distortion premium quality castings
• Easy evaluation with link to GOM

• Process flexibility
• Supports for wide range of casting
processes, as well detailed modelling
of any required part of the process

Copyright © ESI Group, 2023. All rights reserved.

• Early castability checks
• Co-Design supporting assessing risks
early on

• Pro-active correction for OBJECTIVE

downstream risks Help our customers to deliver
• Predicting defects in advance
premium quality castings
• Virtual process chain
securing time-to-market cost

• Quicker user & simulation

turnaround times
• Dedicated foundry process workflows
• (DMP) Scaling on cores

Copyright © ESI Group, 2023. All rights reserved.

 Agenda

1 ESI Casting Solution ProCAST

Introduction

2 Sustain Premium Quality Parts

2023.0 Release Content

3 Cast Early Feasibility

Bridge the Gap between Design and Manufacture

4 Partnerships
Industry Collaboration, R&I

5 What’s next ?
Overview & Solution Roadmap

Copyright © ESI Group, 2023. All rights reserved.

Geometry & Meshing [Visual Mesh Cast]
What’s New in ESI ProCAST 2023?

Copyright © ESI Group, 2023. All rights reserved.

Visual Assembly (Mesh)
An Alternative to CAD-based Approach
• When to use?
• CAD data is not available
• CAD quality data is not acceptable
• CAD based approach not successful/time consuming

Assembled 2D mesh volumes (T sections)

Gaps Display
Individual 2D mesh volumes

Copyright © ESI Group, 2023. All rights reserved.

ProCAST 2023
Meshing
• 3D Mesh quality enhancement
• When to use ?
• When 3D mesh can t be generated
• When user wants to speed up calculation times
Identified areas to enhance
• Workflow:
• 2D Mesh quality check- Addl Intercsetion “Advanced”
• Highlight 2D surface areas to enhance
• Manual Enhancement of 2D mesh areas (a few minutes)
• Generate optimized 3D mesh

→ It has been observed a solver calculation speed

around 15-50%

Local 2D mesh manual repair

Copyright © ESI Group, 2023. All rights reserved.
ProCAST 2023.0
Shelling
• Enhancement in term of mesh
transition in sharp edge areas (less
nodes ).

V2022.0 V2023.0
• Gravity factor handled (beta version)
• Prototype, Enabled through an Env
Variable

Gravity
Copyright © ESI Group, 2023. All rights reserved.
Model & Solvers/Engine [Visual Cast ,Solvers]

What’s New in ESI ProCAST 2023?

Copyright © ESI Group, 2023. All rights reserved.

Volume Orientation
Volume Orientation
• The Volume Orientation definition has been enhanced to handle
local material orientation.

• Two orientation methods:

• Projection Mode
• Preferred for Shell/Insulation
• Z (e3) is the element normal
• Each local frame orientation is transferred to the nearest volume local
frame

• Rosette Mode
• Preferred for alloys (including filters)
• X-Y-Z (e1,e2,e3) local frame axis are defined from the selected rosette

Please see the manual for more detailed information.

Copyright © ESI Group, 2023. All rights reserved.
Mechanical Modeling
Radial & Tangential Stresses
• Volume orientation functionality is used to define local orientation

Local axis e1 Local axis e2 Local axis e3

Local stress11 Local stress12 Local stress13

Copyright © ESI Group, 2023. All rights reserved.
Anisotropy
Material Data
• Anisotropy for Young’s Modulus’s material data can now be defined:

• Use the Anisotropic Tab

• Define Young’s Modulus properties (vs orthotropic values)

Copyright © ESI Group, 2023. All rights reserved.

Material Anisotropy
Youngs’ Modulus
• Young’s modulus’ anisotropic material definition is
now handled.

• Properties are written in d.out file

• New contours are available for the analysis

• Local displacement 1,2 and 3 representing

Displacement in X, Y and Z

• Local Stress 11,12,13,22,23 and 33

representing Sigma X, XY, XZ, Y, YZ and Z

Copyright © ESI Group, 2023. All rights reserved.

CAFE2G
New Kinetics Law
• Support of polynomial function to compute growth rate as a function of undercooling :

• New Inputs:

• Order of Polynome

• Polynomial coefficients
The number of coefficients is equal to the order of
the polynome value.

Copyright © ESI Group, 2023. All rights reserved.

CAFE2G
New Kinetics Law
• Support of polynomial function to compute growth rate
as a function of undercooling :

Parabolic law Polynomial Deg. 4 law

Copyright © ESI Group, 2023. All rights reserved.

Flow Solver
Extended Physics
• VOF Flow solver has been further enhanced :
• Improved fluid/gas interactions handling
• Thermal coupled calculation can now be performed between
alloy (liquid) and air (gas)
• Improved performances Fluid Velocity Magnitude

Gas Velocity Magnitude

Gas Velocity shown in vectors during shot filling phase Gas Temperature

Copyright © ESI Group, 2023. All rights reserved.

Volume Of Fluid
Enhancements
• VOF Flow solver has been further enhanced :

• Solver is launched only if the Reference Pressure

PREF >0

• A study on MPI communication costs reduction and

speedup of the simulation times has been
performed. Using MCPART 1 shows (~5 to 10%)
calculation time speed up.

Copyright © ESI Group, 2023. All rights reserved.

Quadratic Elements
Improved Mechanical Modeling capabilities
• The ProCAST solver has been fully reviewed to handle higher-degree 3D elements.
• Elements: Penta, Pyramid, Hexa
• Solvers: Flow, Thermal, Stress

• Limitations of current version:

• Models with interpenetrated mesh are not handled
• Focus on Investment casting process cases

Linear Elts Non-linear Elts

Copyright © ESI Group, 2023. All rights reserved.
Hot Tear
New Capabilities
• A collaborative work is on going with an automotive customer . Damage only occurs when
location in under « large enough tension »:

• « Large enough » tension threshold = HOTTEAR_COEFF*yield_stress

• HOTTEAR 3 = HOTTEAR 2 controlled by HOTTEAR_COEFF (default 1.0/3.0)
• HOTTEAR 4 = HOTTEAR 1 controlled by HOTTEAR_COEFF (default 1.0/3.0)
Compression area

Traction area

Copyright © ESI Group, 2023. All rights reserved.

ProCAST 2023.0

Induction heating

Default
Heat Treatment

New model

Air entrainment defect Electromagnetism

New model based on free surface motion EMAG for Low/(high) frequency ranges
Enhanced part quality validation Extended casting process modeling capability

Copyright © ESI Group, 2023. All rights reserved.

ProCAST 2023.0

A 3 step workflow

e
Inorganic core gassing & t o typ le)
Quik Quote Pro ariab
drying E n v. V
(
New capability for extended process modeling Specific workflow to evaluate/quote parts
for die castings
Copyright © ESI Group, 2023. All rights reserved.
Good DMP Scalability up to 32cores
High Productivity Total Weight
1900 Kg
• Filling+Solidification+Mechanical modeling

Simulation
DMP Speed-Up
Time in Hours

Copyright © ESI Group, 2023. All rights reserved.

Multiple Die Spray

• Handling of multiple Die Spray is now possible in QuikCAST

1st Spray

2nd Spray

Copyright © ESI Group, 2023. All rights reserved.

Simulation Results [Visual Viewer Cast]

What’s New in ESI ProCAST 2023?

Copyright © ESI Group, 2023. All rights reserved.

 Result Analysis
Multi-Scale

Checking Porosity for casting with shell temperature

Checking velocities in casting with inserts temperature

Enhanced Capability of analysis

different results on the same view.

Checking casting solidification and shell temperature Copyright © ESI Group, 2023. All rights reserved.
Multiple Entity Info

• It is now possible to view multiple entity info :

• Dedicated GUI in the tool bar
1 entity
Multiple entities
Delete All Entities

• Customization is possible through Annotation panel

• New Button to add Nodes from Entity Info in the plot area

Copyright © ESI Group, 2023. All rights reserved.

Display at Mold Surface

• A new option is now available in order to see an alloy result applied on

the mold surface for better usability
• Menu “Results”
• Enable “Display on Mold Interface”
• A new “User Defined result” is created

Temperature at core interf ace

FS at core interf ace

Temperature at shell interf ace

Copyright © ESI Group, 2023. All rights reserved.

Results Synchronization

• Synchronization can now also be done on:

• %Fill
• %Solid

%Solid synchronized

%Fill synchronized

Copyright © ESI Group, 2023. All rights reserved.

 Agenda

1 ESI Casting Solution ProCAST

Introduction

2 Sustain Premium Quality Parts

2023.0 Release Content

3 Cast Early Feasibility

Bridge the Gap between Design and Manufacture

4 Partnerships
Industry Collaboration, R&I

5 What’s next ?
Overview & Solution Roadmap

Copyright © ESI Group, 2023. All rights reserved.

Cast Early Feasibility
Co-Design module

Copyright © ESI Group, 2023. All rights reserved.

Cast Early Feasibility
Co-Design Enables quick CASTABILITY check
Wall Thickness Thickness Transition Solidification Solidification Time

Project
Sharp Edges Draft Angle (X/Y/Z)
Defects Thermal Modulus Description

Geometrical
Approach

Thermo-mechanical
Shell Bridge Risk Approach
Indicator Thermo-mechanical

Tailored
Post-Processing

Thermal/Mechanical
Geometrical Approach
Approach
Copyright © ESI Group, 2023. All rights reserved.
Cast Early Feasibility Geometrical Approach

Geometry Validation Example

✓ Quick Castability Check
✓ Geometrical Design
✓ Critical Sections
✓ Tooling Complexity, …

Draft Angles
Thickness Analysis

Sharp Edges

Copyright © ESI Group, 2023. All rights reserved.

 Cast Early Feasibility Thermal Approach

Geometry Validation Example Porosity ✓ Quick Castability Check

✓ Part solidification
✓ Defects
✓ Deformations , …
Thermal modulus
Solid Fraction (%) – X-Rays

Solidification time

Copyright © ESI Group, 2023. All rights reserved.

Cast Early Feasibility
Co-Design Module

• More information:

https://www.esi-group.com/events/2020/co-design-for-casting-a-bridge-between-product-designers-buyers-manufacturers

• An article about successful implementation:

https://www.esi-group.com/blog/how-do-rolls-royce-engineers-make-sure-their-designs-are-fully-castable

Copyright © ESI Group, 2023. All rights reserved.

 Agenda

1 ESI Casting Solution ProCAST

Introduction

2 Sustain Premium Quality Parts

2023.0 Release Content

3 Cast Early Feasibility

Bridge the Gap between Design and Manufacture

4 Partnerships
Industry Collaboration, R&I

5 What’s next ?
Overview & Solution Roadmap

Copyright © ESI Group, 2023. All rights reserved.

ESI & Industry Collaboration
Select the right Virtual Die
Casting Machine

Integration of Die
Casting Machine &
ProCAST

Real Time Piston Control

Machine Performance

Copyright © ESI Group, 2023. All rights reserved.

ESI & Industry Collaboration

Selected collaborations for enhanced material data

Copyright © ESI Group, 2023. All rights reserved.

ESI & Research Projects

Topological Optimization

Copyright © ESI Group, 2023. All rights reserved.

 Agenda

1 ESI Casting Solution ProCAST

Introduction

2 Sustain Premium Quality Parts

2023.0 Release Content

3 Cast Early Feasibility

Bridge the Gap between Design and Manufacture

4 Partnerships
Industry Collaboration, R&I

5 What’s next ?
Overview & Solution Roadmap

Copyright © ESI Group, 2023. All rights reserved.

 What’s Next?
ESI ProCAST 2023.0

Maturity
(Selected topics)
Released
Charter Prog. Geometry:
ProCAST 2023.0 and beyond High Fidelity
Prototype
- 3D mesh quality enhanced
- Shelling takes into account the gravity factor (proto)
Maturity

R&I
Time Model build:
- Optimization: X&Y simultaneous modification
- Introduction of notion of EVENT (time, cycling)
- New volume orientation GUI (anisotropy)
Geometry: - Visual Cast performances enhancement
- HPDC Gating Design (Salsa3D migration in Visual) - Quik Quote for die casting (Prototype)
- CAD kernel for geometry check/clean/repair
Solvers:
- Enhanced mechanical modeling with quadratic elements
Solvers:
- New Air entrainment model (free surface motion)
- Iterative stress solver (Crash stress solver)
- Density as UF, Enclosure BC as UF
- Model reduction (PGD/MOR)
- Handle Min./Max. displacements
- Handle Material behaving differently in traction &
compression (Drucker Prager)
- Radial & Tangential stresses calculation
- Inorganic core blowing + gassing
Model Build: - New kinetics law for CAFE2G
- Model version + results comparison - New Hot tearing models
- Electromagnetism capabilities (hot tearing)
- Enhanced automatic HTC display for QuikCAST
Analysis:
Solvers: - Results storage space optimization
- Hybrid twin for casting - Enhanced smooth display rendering

Time

Copyright © ESI Group, 2023. All rights reserved.

ESI Casting
R&I Activities

type k
to r The foundation for Admore
PGD/MOR P r o r m wo Real time Space Process Exploration
n g -te
Lo
Copyright © ESI Group, 2023. All rights reserved.
 ESI ProCAST ROADMAP

Prototype Commercial Release

JUL JUL JUL JUL

2022 2023 2024 2025
Extended flow solver capabilities Enhanced mechanical modeling
(VOF thermal coupled) (quadratic elts handling) * ICME Thermo-physical calculations
(3rd part engine coupling) *
New Air entrainment defect model New Air Entrainment defect model
ProCAST (based on free surface motion) (based on free surface motion) Space Exploration for
Migration to new Casting *.
Gravity Die Casting - Foundry Inorganic Core gassing and
oriented workflow drying modeling iterative stress solver Macrosegregation model
TTT/CCT metallurgical (focus on steel) *
1D cooling channel optimization Electro-magnetism module diagrams handling *
3D solid CAD kernel for 3D solid CAD kernel for
Risering Optimization See previous slide…
topology check & repair * topology check & repair *

Air Entrainment defect modeling Multiple Die Spray handling

QuikCAST Migration of QuikCAST to ProCAST Migration of QuikCAST to ProCAST
Gravity Die Casting - Foundry Extended Heat Transfer Coeff
oriented workflow display CMX architecture * CMX architecture*
Quik Start workflow *
Risering Optimization
(sales quote)

Thermo-mechanical coupled Die Casting HPDC Gate Design

calculations (full Salsa3D transfer) *
Co-Design / Gate Design Automatic report generation
(geometry & modeling)
Die Casting HPDC Gate Design Co-Design for Die Casting HPDC
Usability enhancement
Handling of symmetrical models (full Salsa3D transfer) * (including HPDC Gate Design) *

* Subject to revision
Copyright © ESI Group, 2023. All rights reserved.
GIFA Event

Copyright © ESI Group, 2023. All rights reserved.

ESI trademarks, which include logos, are intellectual property and are considered assets of the corporation. Their protectabi lity is dependent upon consistent and proper usage. Everyone, whether ESI employees, consultants, outside vendors
or third parties who are involved in developing the ESI communication, is responsible for using ESI Group’s and others’ trademarks correctly. This includes internal and external documents, both in traditional and electronic forms.

esi-group.com

© ESI Group 2023