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HITACHI ADSTEFAN casting simulation system

HITACHI ADSTEFAN casting simulation system

ADSTEFAN is casting simulation software sold by HITACHI in Japan. It boasts the industry’s fastest simulation analysis speed and comes with a rich JIS material database, allowing simulation for specific material usage. Prior to conducting casting simulations, users only need to select the desired material, and relevant parameters will be automatically applied when starting the simulation.

Software Introduction

For all Engineers who desire to make better product.

How molten metals flow and solidify inside a mold has long been a black box.

ADSTEFAN is a support tool that enables you to reduce defects, reduce costs, and reduce the number of prototypes by visualizing the casting process on your computer through simulations.

In developing the system, our policy has been to create a product that does not just serve analysis specialists, but rather can be easily used by everyone involved with casting technology.

It is a policy that will never change as we continue our development of ADSTEFAN.

Our mission will continue to evolve without change.

ADSTEFAN has three major advantages: high-speed analysis, reliable base, and easy operation.

  • High-Speed Analysis

    Casting simulations are tools for computer-based trial-and-error experimentation to discover which casting methods and conditions will be the most rational and result in minimal defects when casting.

    Doing so requires multiple analysis, and it is hard to measure the actual impact of time spent on analysis in any given case. Its reputation as a leading tool for high-speed analysis is long-standing, but with its newly added parallel computing and large-scale analytical technology, ADSTEFAN substantially reduces analysis time even further.

  • Solid Foundation

    The know-how of experienced technicians from over 30 casting companies was gathered together in Tohoku University’s cooperative industry-academia project, the “Casting CAE Research Society (Stefan Group)”. After the passage of roughly 7 years, the fruits of the society’s research and development were made into a commercial product through Tohoku Techno Arch Co., Ltd., a Technology Licensing Organization (TLO), to become a highly-reliable casting simulation system.

    With routine user support as well as user conferences and technical seminars where engineers using ADSTEFAN exchange information on the one hand, we have extended our industry-academia partnership to include users and fuse the latest user needs with the seeds of cutting-edge research in pursuit of new features and ever-greater ease of use.

    Newly developed features are distributed to users in accordance with the ADSTEFAN Support Services Contract and user evaluations from feedback during follow-ups are reflected in new areas of ADSTEFAN development.

    In recognition of this partnership, we were given the 8th Award for Persons of Merit Industry-Academia-Government Collaboration, awarded in 2010 by the Japanese Ministry of Education, Culture, Sports, Science and Technology(Japan).

  • Easy Operation

    ADSTEFAN’s unified GUI provides access to a full range of processes, from importing CAD data to generating meshes, configuring analytical conditions, and evaluating results.

    Its ability to share data(CAD, mesh, material properties, analysis results, etc.)between individual tools makes it possible to simultaneously manage all processing flows related to an analysis.

    The system’s unified operating environment makes it easy to perform comparisons between existing analyses and new ideas, and by enabling data to be shared with external analytical tools and allowing optimization engines to be incorporated into the design optimization system, it also makes possible the development of various casting design processes.

System overview

ADSTEFAN consists of pre-processor, solver, post processor and utility.

Mesh creation – Condition setting – Analysis execution – Result operation can be operated smoothly, and many customers have patronized us.

In addition, it can be used for various casting processes (die casting (squeeze, semi-solidification), gravity casting (sand mold / mold), low pressure casting, inclined casting,centrifugal casting, precision casting, lost wax casting, electro slag remelting (ESR)) It corresponds.

  • Pre-processor

    Creates analytical models by generating computational mesh and configuring analysis conditions and result output.

    Automatically corrects for surface omissions, overlaps, inversions and other such errors in STL data.

    Automatically configures physical property condition needed in the analysis by simply selecting the means of casting and mold materials from the included database.

    Automatically verifies configuration settings (e.g.physical property limitations) to avoid work that must be redone due to input errors.

  • Solver

    • Fluid Flow Analysis

      Analyzes how molten metals flow into and fill the mold. Its filling status, pressure, temperature changes, and other parameters can be simulated, enabling optimal plans to be designed.

      The accuracy of the flow of the curved surface which is considered to be weak by the direct difference method is also subjected to unique difference correction processing, and improvement of straightness and accuracy is aimed at.

      Moreover, various options such as gas-liquid two-phase flow consideration, molten metal behavior in sleeve, consideration of inclination, centrifugation consideration are carried.

    • Solidification Analysis
      Analyzes how molten metals solidify in the mold. By visualizing the progression process of solidification, we support wall thickness design and riser design.By accounting for changes in the volume of molten metal during solidification, macro-shrinkage cavities occurring during solidification, as well as cavity shapes and sizes, can be predicted.Moreover analysis for cast iron that local pressure and considers super-cooling can also be performed.

    • Die Temperature Analysis
      If processes such as shot processes, die opening, product removal, and blowing are provided as input, analysis of die temperature changes during repeated casting is performed. Its support safe mold design.It is possible to investigate the proper number of times to throw away until reaching a steady state and predict the risk of die damage during the process.Die surface temperature changes due to parting agent spray functions, and internal die temperature changes due to water-cooled tube flow rate settings, can be analyzed. Furthermore, spot cooling can also be evaluated.

  • Post Processor

    Combines CAD data and volume rendering methods to provide high-speed, high-precision display of visual data necessary to evaluate results.

    Scaling function, measurement function, result synchronization function, animation output function, report output function etc. are carried.

    By using cross section display, semitransparent display, etc., we visualize the part to be evaluated in an easy-to-understand manner.

  • Utility

    Various utilities are installed so that ADSTEFAN can be used more meaningfully, such as processing analysis results and cooperation tools with external analysis systems.

    By using the property value matching tool and the overlay display function with X-ray imaging data, it is possible to accurately evaluate the deviation between the actual data and the analysis result.

System requirements

Case study

  • Die-casting/Evaluation of filling behavior in

    • Temperature distribution during filling
    • Air behavior during filling
    • Movement of initial inclusions
  • Die-casting/Analysis of Molten Metal Behavior

    • Air contact time during filling
    • Molten Metal Behavior Inside Sleeves
    • Temperature distribution of plunger tip
  • Thixomolding/Evaluation of Cold Shut

    • The contribution of each gate
    • Defect and analysis result comparison
  • Sand casting/Shrinkage analysis

    • Shrinkage (RiserΦ120mm)

    • Shrinkage (RiserΦ160mm)

  • Sand casting/Comparison of molten metal

    • Actual measurement
    • Analysis result