SOLIDCast UNIT 42: Tilt Pour
SOLIDCast lets you set a starting and ending angle to simulate tilt pouring. Tilt pouring is used primarily in the permanent mold process, and involves the gradual tilting of a mold from a horizontal to a vertical position in order to provide a relatively quiescent fill and also to promote strong temperature gradients and directional solidification within the model. Generally, a basin of liquid metal attached to the mold is filled while the mold is in a stationary position, and then the mold is tilted upright in a controlled process, gradually filling the mold cavity.
Setting up the tilt pour process involves specifying the starting and ending orientation of the mold as angles rotating about either the X axis or the Y axis. It is necessary to have a shape of Fill Material (see the chapter on Mold Filling) that represents the entry location of the molten into the mold. The system assumes that the Fill Time is equal to the Tilt Time. In other words, if you specify a Fill Time of 15 seconds, the system will assume that the time from start of tilt until end of tilt is 15 seconds and that at the end of this time the mold cavity is full of liquid metal. The Early Fill Tilt Pour utility can be used to modify the process, if fill time and tilt time are not the same. See the Stand-Alone Utilities Unit for details.
We highly recommend that the model of the casting and model be constructed so that is in the correct orientation at the end of tilting. The default orientation in the system is that +Z represents UP and Z represents DOWN . Keeping this in mind, construct your model so that the mold is in the correct orientation at the END of the tilting process, i.e., when the casting is solidifying. This makes it easier to properly set the tilt pour angles and interpret the results.
The key to using the Tilt Pour Angles is to remember that, when you are setting them, you are specifying to the system which direction is DOWN at the start and end of tilt. The model itself does not actually rotate. When the simulation is running, the system gradually changes an internal vector that indicates the direction of gravity, to simulate the tilt pour process. Therefore, using the Tilt Pour Angles feature, you are indicating on the current model, as it is currently oriented, which direction is DOWN at the start and at the end of the tilting process. As stated previously, we recommend that the model be oriented such that it is the correct default orientation (-Z down) at the end of tilt. This means that the ending angle for tilt pour should be 0.
Note that if you use the optional FLOWCast module, tilt pour parameters will be used, and you will actually see the casting rotate during the filling process.
To use the Tilt Pour feature, you should have the model displayed in SOLIDCast. Setting of Tilt Pour angles MUST BE DONE PRIOR TO MESHING THE MODEL. The Tilt Pour Angles will not be active if you set them AFTER meshing the model.
Select Model from the main menu, then select Options. You will see a window which has two tabs, one for Planes of Symmetry and one for Tilt Pour. Select the tab labeled Tilt Pour. You should see the following on the screen:
To activate Tilt-Pour, click on the box labeled Tilt-pour enabled . You then have the option of rotating the tilt-pour arrows around either the X axis or the Y axis. You can set an angle for the Start position and another for the Stop position. (Remember, we recommend that the model be constructed so that the Stop position is the default position with Z as down.)
The angles are pointing in the direction that is considered to be DOWN on the model at the start of tilt and at the end of tilt. The arrows are moved by adjusting the slider bars on the right.
Rotation around the Y axis would appear as follows:
Rotation about the X axis would appear as:
As an example, suppose that we have created a model as follows:
This model has been oriented such that it is in the correct, UPRIGHT position at the end of tilt, i.e., the Z direction is considered to be DOWN at the end of tilt. The Stop angle would then be set to 0 degrees, since there would be no rotation from the default Z direction at the end of tilt.
The question then is how to set the Start angle for this model. As shown, the model as it has been constructed would rotate about the X axis during the tilt. The direction which is DOWN when the mold is in the Start position is the +Y direction on the model in its current orientation (remember, we are specifying which direction would be DOWN on the model, as it is CURRENTLY ORIENTED, when it is in the Start position). Therefore, we would want to set the Start angle to the +Y direction on this model. This would appear as follows:
The rotation is about X, and the Start angle is set to 270 degrees, which we can see from the display is in the +Y direction.
Be sure to press the “Apply” button to activate your selection of Tilt Pour angles.
Once the Apply button has been pressed, the tilt pour setup is enabled and any simulation involving filling, using SOLIDCast or FLOWCast, will use these parameters.