Procast Manual

Based onProCAST™

Version 3.1.0

ProCAST™

USER’S MANUAL & TECHNICAL REFERENCE

ProCAST User’s Manual & Technical Reference. Copyright © 1996,1997 by UES Software, Inc. All rights reserved. Printed in the UnitedStates of America. No part of this manual may be used or reproduced inany manner whatsoever without written permission. For informationaddress UES, Software Inc., 4401 Dayton-Xenia Road, Dayton, Ohio45432-1894, USA. Telephone: 937-426-6900

The following are trademarks or registered trademarks of theirrespective companies or organizations.

PATRAN--PDA EngineeringNASTRAN--MacNeal Schwendler CorporationI-DEAS--Structural Dynamics Research CorporationPARASOLIDS--Unigraphics Corporation

UES SOFTWARE, INC. TECHNICAL DOCUMENTATION USER’S MANUAL & TECHNICAL REFERENCE

PROCAST USER’S MANUAL PAGE I

TABLE OF CONTENTSINTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1General Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6Graphical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9Typographic Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11Next Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11STARTING ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13DATABASE FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17TABLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23VIEWING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26

SETTING-UP PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1General Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1Fluid Flow Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2

Mesh and Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3Run Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5

Radiation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5Micromodeling Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6Simulating an Al-7% Si Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8Inverse Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11

USING PreCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2

CREATE 2-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11DEL LINE-ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13DEL REGION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16MESH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 19QUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20REGION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21RESTORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23SPLIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24SMOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25

SYMMETRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 26GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28CENTRIFUGAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32CHECK GEOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36AXISYM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 41VIRTUAL MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 42

MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 44DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 46

THERMAL PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 51FLUID PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 55

FILTER PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 60ELECTROMAGNETIC PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61

ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 64STRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 68

MATERIAL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70


PROCAST USER’S MANUAL PAGE II

PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75

MICRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77CAFE MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 82COUPLED EUTECTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83DUCTILE IRON EUTECTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 87DUCTILE IRON EUTECTOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 89EQUIAXED DENDRITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 90GRAY IRON EUTECTOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94GRAY/WHITE IRON EUTECTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 95PERITECTIC TRANSFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 97SCHEIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 102SOLID TRANSFORMATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 104

INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 110INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 111

DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 113CREATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 119ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 121MULTI-POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 124INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 128

BOUNDARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 129DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 131

CURRENT DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 135DISPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 136HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 137INJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 140MAGNETIC POTENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 141MASS SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 142MOMENTUM SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 143POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 144PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 145SURFACE LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 146SURFACE NUCLEATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 147TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 148TURBULENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 149VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 150VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 152VOLUMETRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 153

ASSIGN SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 154ADD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 156ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 156COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157DELETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157DESELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157REMAINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 158SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 158SELECT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 159STORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 159SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 159

ASSIGN VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 161CURRENT DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162MASS SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162MOMENTUM SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162SURFACE HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162VOLUMETRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162

PERMEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 164INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 165


PROCAST USER’S MANUAL PAGE III

RADIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 166DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 167

EMISSIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 171TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 172VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 173

ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 174ADD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 175ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 175DELETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176DESELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176SELECT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176STORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 177

SOLID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 178INITIAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 180

CONSTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 182EXTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 183FREE SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 185

RUN PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 186UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 188GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 189THERMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 195RADIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 199FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 202TURBULENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 210STRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 212ELECTROMAGNETIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 214INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 216CAFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 218

USING DataCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1

USING ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1

USING PostCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3

X-Y PLOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16RADIATION FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23HEAT FLUX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 24R, G, L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25FEEDING LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29ISOCHRONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31ALPHA CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 34SDAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36ROW SUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 38FACE TO GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 39

FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 40STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 41UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 43MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 45

USING ViewCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1CONTOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4VECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16


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MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31PAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38

USING INVERSE MODELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

APPENDIX AINSTALLING ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 5

APPENDIX BProCAST FILE USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1

PreCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1DataCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 1ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 2PostCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 3ViewCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B - 4

APPENDIX CMATHEMATICAL FORMULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1Section 1: Energy Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 1Section 2: Continuity Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 2Section 3: Momentum Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 2Section 4: Turbulent Kinetic Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 3Section 5: Turbulence Dissipation Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 4Section 6: Eddy Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 4Section 7: Non-Newtonian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 4

Section 8: Initial and Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 7

Section 9: The View Factor Radiation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 10

Section 10: Finite Element Discretization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 12Conduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 12Momentum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 13Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 15

Section 11: Time Stepping Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 16Section 12: Electromagnetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 18Section 13: Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 20

Governing equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 20Thermal-Mechanical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 20Variational Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 21Finite Element Discretization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 21

Stress Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 22

Radial return mapping algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 25Section 14: Preconditioned Conjugate Gradient Solver . . . . . . . . . . . . . . . . . . . . . . . . . . C - 26Section 15: Preconditioned Conjugate Residual Solver . . . . . . . . . . . . . . . . . . . . . . . . . . C - 29Section 16: Micromodeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 30

Equiaxed Dendrite Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 30Coupled Eutectic Growth Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 33Ductile Iron Eutectic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 36Gray Iron Eutectoid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 44Peritectic Transformation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 45Solid Transformation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 47Scheil Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 49Output of Micromodels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 50


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Equiaxed Dendrite Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 50Coupled Eutectic Growth Model with Instantaneous Nucleation . . . . . . . . C - 50Coupled Eutectic Growth Model with Continuous Nucleation . . . . . . . . . . C - 51Ductile Iron Eutectic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 52Gray/White Iron Eutectic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 52Ductile Iron Eutectoid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 53Gray Iron Eutectoid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 53Peritectic Transformation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 54Solid Transformation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 54Scheil Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 54

Interlamellar spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 55Section 17: Cooling Curve Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 57

APPENDIX Dprefixd.dat FILE FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1

APPENDIX EMATERIAL PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1

APPENDIX FSTRESS MODEL PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1

APPENDIX GBOUNDARY CONDITION PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . G - 1

APPENDIX HINTERFACE PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1

APPENDIX IRADIATION PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - 1

APPENDIX JMATERIAL MICROMODEL PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . J - 1

APPENDIX KINVERSE MODELING FILE FORMATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1Inverse settings file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1Measurement file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 3

APPENDIX LINSTALLING INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1

INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1


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INTRODUCTION

INTRODUCTION, PAGE 1 - 1

CHAPTER 1

INTRODUCTIONPurpose ProCAST™ models industrial casting processes and provides tools

which may be applied to the analysis of a wide variety of fully coupledthermal, fluid, stress, and microstructure prediction problems. Thisadvanced suite of software modules uses the Finite Element Methodand comprehensive solvers to capture all the physics of the castingprocess and lets you see the effects of design decisions . . . on thecomputer. Complex geometries including the casting, dies, molds,risers, gates, and chills can be evaluated as a complete system or theymay be isolated, depending upon your individual project-specific needs.

This User’s Guide and Technical Reference is designed to explain howto use ProCAST, its functions, and options which are available to you.

About ProCAST ProCAST is and has been the technology leader in the castingsimulation market for many years. Key attributes which havecontributed to this leadership position are enhanced in the newestrelease of ProCAST. Some of these attributes are discussed here.

Flexibility: ProCAST can provide both process-specific and analysis-

specific simulation support. ProCAST models Sand, Permanent Mold,Low/High Pressure Die, Investment, Expendable Pattern, andContinuous casting processes. ProCAST provides fully coupledthermal-fluid-stress analyses. ProCAST’s micromodeling featureprovides the capability to predict the microstructure of castings. Giventhe required and appropriate material property data, virtually any castmaterial can be accurately modeled.

Graphical User Interface: ProCAST’s graphical user interface has been

standardized and structured to guide you through the process forsetting-up, running, and analyzing simulation problems. The databasefacility, table maintenance, and viewing tools are examples of theimplementation of this enhanced user interface. The consistent use ofvisual clues and objects make it easier to concentrate on the castingproduction problem to be solved.

Database Facility: Database capabilities have been integrated into the

components of ProCAST. You access the Database Facility throughpush buttons which appear in selected menus of ProCAST’s functionsand components. This facility provides a standardized approach formanaging the data associated with your models, whether it is amaterial, interface definition, boundary condition, or other property orattribute. The nature of the information placed in the database dependsupon the material, property, attribute, and/or intended use of the data.

Results: Post-simulation processing is robust. ProCAST provides the

INTRODUCTION

PAGE 1 - 2 PROCAST USER’S MANUAL

capability to extract and view a comprehensive range of contour andvector plots. For 3D problems, you may view the results from surfaceand/or internal perspectives at user defined cross-sections. ProCAST’svisualization tools provide the capability to produce animated views ofthe casting process. These animated displays of material flow and theevolution of strain and temperature in the model, for example, providefurther insight into your process, materials, and finished products. Youmay also export simulation results for analysis with other tools.

Benefits: ProCAST provides the tools to help you build a quality

product. The bottom line to any “high-tech” asset is its ability tocontribute to your business success. The following are just a fewexamples of how ProCAST can assist you in achieving these vitalbusiness objectives. • Reduce costs • Increase yields • Improve quality • Improve quotes • Shorten cycle times • Boost sales

Analytical Application ProCAST is a powerful tool to help you engineer your process . . . tomake castings with the required shape and properties, the first time andevery time. When you “cast it first on the computer,” you avoid thecostly shop floor trial-and-error approach of the past. Some of theanalytical capabilities you may apply to your process include: • Heat flow: ProCAST handles all three primary modes of heat

transfer--conduction, convection and radiation. It also allowsyou to account for phase changes (melting, solidification, andsolid-state transformation) and internal heat generation ordissipation.

• Fluid flow: ProCAST offers outstanding fluid flow capabilities forsimulating mold filling. It handles any type of filling, including:plastics, waxes, powdered metals, and the very high velocitiesencountered in high pressure die casting. Turbulent flow,compressible flow, as well as non-Newtonian flow can behandled. Vents, trapped gas, low pressure casting, lost foamprocesses, the use of filters, and centrifugal processes can allbe accurately simulated.

• Stress and Strain: ProCAST calculates thermally induced stressessimultaneously in all components of the simulation with linearelastic, elasto-plastic, or elasto-viscoplastic models. Residualstresses, plastic deformation, hot tears, and final shape of thecasting can all be predicted. ProCAST also automaticallydetermines gap formation which results from the heat flowacross the interface between the casting and mold in coupledthermal/stress analyses.

• Radiation: The advanced radiation module calculates net radiosityusing the diffuse grey body approximation technique. Viewfactors, including the shadowing effects, are automaticallycalculated. The enclosure can move with respect to the casting

INTRODUCTION


and the view factors are automatically updated. ProCASTautomatically selects the element faces of the casting which areparticipating in the radiation model. This capability greatlysimplifies problem set-up.

• Microstructure modeling: Using deterministic modeling, ProCASTcouples the thermal history at any location in a casting with thenucleation and growth of microstructures. The micromodelswhich have been implemented in ProCAST are designed to beapplied to most industrial alloys and are fully coupled with themacro heat transfer solution.

• Inverse modeling: Calculates selected material properties by usingthe numerically generated thermal history and measuredtemperatures. The inverse solver calculates the optimummaterial property which will give the best match between themeasured and calculated cooling curves for the material.

• Electromagnetics: ProCAST is capable of fully coupled thermal/fluidflow/electromagnetic calculations for induction heating andelectromagnetic stirring processes. ProCAST solves theMaxwell Equations using a magnetic vector potential approach.

• High quality tet mesh: ProCAST automatically generates the meshfor 2D and 3D problems. Geometries which have beenproduced in a commercially available CAD and CAE packagesmay be used as input for ProCAST. The MeshCAST moduleprovides the capability to read these geometries, evaluate andrepair these geometries, and generate either a 2D or 3D meshfor use in ProCAST.

Software features The suite of tools available to you is governed by your software license. Your professional judgement and individual research, design,development, or analysis requirements govern which of the availabletools you will use. The ProCAST suite is composed of six softwaremodules. These six software modules are briefly described below.

PreCAST--performs pre-simulation processing by providing thecapability to define the problem. This includes importing orcreating geometries, defining the materials, interfaces,boundary conditions, initial conditions, planes of symmetry, andrun parameters. PreCAST also provides the capability todescribe radiation data and apply this data to enclosures andmoving solids.

DataCAST--reads the problem definition data created by PreCAST,checks the problem definition for errors, converts all units intoCGS units and creates the binary files which will be read by thesimulation module, ProCAST. If errors are encountered, theywill be displayed on the workstation. They will also be written ina file.

INTRODUCTION


ProCAST--simulates the casting process, performs the finite elementanalysis, and generates process results. This data may then beprocessed for viewing and analysis.

PostCAST--provides the post-simulation capability to view X-Y plots,calculate derivative results, and selectively extract data fromthe simulation results files and format this data for furtherprocessing, analysis, or viewing.

ViewCAST--provides the capability to view the results of the simulation. It performs rapid contour plots of all results. For example,temperature contours can be plotted at every time stepautomatically, giving an animated effect. Also, a cutting planeoption allows you to see inside the casting. Menus allow you tochoose views from an extensive list of contours and vectors.

MeshCAST--provides the capability to import geometries fromcommercially available CAD and CAE packages, evaluate andrepair the models, and generate a high quality tetrahedral meshfor use in ProCAST and other FEM analysis software programs.

Technical Features ProCAST offers sophisticated and powerful technology for simulatingyour casting and casting process problems. Some of the distinctivefeatures of this technology are discussed below.

Outstanding fluid flow capabilities for casting simulations areimplemented. The full 3D Navier-Stokes equations are beingsolved with no short cuts, along with the coupled energyequation. A novel implementation of the Volume of Fluidapproach has been used for handling the free surface flowduring and after filling. Natural convection and shrinkageinduced flow are modeled, if desired, throughout thesolidification process.

A unique method for calculating radiation view factors has beendeveloped for use in ProCAST. It offers radical improvementsin computational efficiency over previously existing techniques. It is now feasible to recompute view factors which are changingwith time ( as in directionally solidified investment castings ).

Complex geometries may be generated using the multi-pointconstraint feature. This feature allows you “glue” togetherpieces of a finite element mesh which do not match. Thus, acoarse mesh in one region may be joined to a fine mesh in asecond region without a transition. Furthermore, the constraintweighting factors are generated automatically.

Accurately model the phase transformation of any alloy or pure metal,

INTRODUCTION


to the extent that the fraction solidified function has beenquantified, using the enthalpy formulation employed inProCAST. The latent heat evolution cannot be bypassed with atime step which is too large.

Select an implicit mode for the casting and an explicit mode for thedie with little restriction on time step size using the two-leveltime stepping algorithm. The consequence is a substantialsavings in CPU time, particularly if there are many elements inthe die.

The interface heat transfer between the casting and the mold is adominant rate controlling mechanism. UES engineers havedeveloped a very accurate and efficient coincident nodemethodology for modeling this phenomenon. Time and/ortemperature dependent coefficients can be accommodated. Again, automatic selection of faces makes life easier for theProCAST user.

Specific technical capabilities of ProCAST include the following: • Efficient solution of transient Navier-Stokes and energy equations

in three dimensions by the finite element method • Volume of Fluid approach for handling the free surface flow in filling

transients • Turbulence modeling using the �� two equation approach • Trapped gas model accounts for vents and sand permeability • Solves transient, nonlinear heat conduction in three dimensions • Solves the conjugate heat transfer problem with conduction in the

solid along with fluid flow • Non-Newtonian flow, with viscosity as a power law function of shear

rate • Solidification kinetics and solid state transformations, i.e.

micromodeling • Elastic, elastoplastic, and elastoviscoplastic stress analysis,

coupled with thermal-fluid analysis • Eddy current heating, Electromagnetics • Enthalpy formulation for handling phase change • Preconditioned conjugate gradient equation solver • Implicit-explicit, two-level time stepping algorithm with automatic

step-size control • Temperature dependent density, conductivity, specific heat,

viscosity, and emissivity • Coincident and non-coincident node techniques for modeling the

casting-mold interface • Time and/or temperature dependent interface heat transfer

coefficients • Automatic generation of coincident node faces • Time dependent temperature, pressure, and velocity boundary

INTRODUCTION


conditions • Time and/or temperature dependent film coefficients for flux

boundary conditions • Pressure dependent velocity boundary conditions • Diffuse, gray body radiation model • Automatic view factor calculations with moving relative surfaces • Radial and mirror symmetry options available in the radiation model • Hexahedral (brick), tetrahedron, wedge, quadrilateral, and triangular

elements • Multi-point constraints • Automatic calculation of isochrons, temperature gradients,

solidification rates, and cooling rates • Automatic calculation of metallurgical indicators for porosity, grain

size and morphology, etc. • Temperature-time curve plots • Fraction solid-time curve plots • Sophisticated contour and vector plotting program for viewing all

results • Interfaced with PATRAN, IDEAS, IFEM, GFEM, ProEngineer,

ANSYS, ARIES and ANVIL for mesh generation

The path to follow to take advantage of these and other capabilities inProCAST, from initial problem definition to analysis of the results, isstraight-forward and typically follows the workflow described below. Within the framework of this general workflow, ProCAST offers avariety of tools and methods which may be used to help you refine yourmodel and generate high quality analyses of your casting process.

This manual will introduce you to the general ProCAST workflow andprovide detailed information about specific commands, functions,keywords, and operations.

General Workflow The work steps which you follow when using ProCAST depend upon thenature of your project, your intended use of the results generated byProCAST, and the type and quality of model you use as the initial input. The general workflow, outlined below, illustrates the six general stepstypically followed in a complete ProCAST project.

Step One: Load or create a modelEvery ProCAST project begins by obtaining a solid mesh of theobjects to be analyzed. ProCAST allows you to: 1) read solidmeshes which have been created in commercial packages suchas PATRAN, IDEAS, ANVIL, ANSYS, ProEngineer, IFEM, andGFEM; 2) sketch 2D geometries and generate a 2D solid meshwith PreCAST’s CREATE 2-D functions; or 3) read an IGESdescription of a geometry’s surface into MeshCAST andgenerate a 2-D or 3-D solid mesh.

INTRODUCTION


The solid mesh of the model should contain, as a minimum, thefollowing information: • Nodal x, y and z coordinates, • Element connectivity, and • Material number assigned to each element.

These options and methods are described in detail in the UsingPreCAST section of this manual.

Step Two: Set-up the problemPreCAST is used to set-up the problem. Materials, boundaryconditions, interfaces, radiation, and initial conditions aredefined using PreCAST capabilities. Once these componentsof the model are defined, they may be assigned to specificmesh elements or groups of mesh elements.

Step Three: Check the modelDataCAST reads the problem definition data created byPreCAST, checks the problem definition for errors, converts allunits into CGS units, and creates the binary files which will beread by the simulation module. If errors are encountered, theyshould be corrected before proceeding with the simulation step.

Step Four: Run the simulationThis step actually runs the ProCAST solver. This step involvesmost of the cpu-intensive computation and is typically run as abatch mode background job.

Step Five: Extract the desired resultsThe results of the simulation done in step four will be containedin a variety of files and, in most cases, represents a largevolume of data. The unformatted results files are processed inthis step by PostCAST or ViewCAST to extract the specificinformation you need for your analysis.

Step Six: View the resultsViewCAST is a collection of tools and displays which allow youto visualize the results of the simulation. Steps five and sixmay be repeated as necessary to provide views of the resultswhich best meet your specific needs.

Graphical Interface ProCAST uses a graphical interface to facilitate input and interactionbetween you and the components of ProCAST. When the PreCAST,PostCAST, and ViewCAST modules are activated, the work space isfilled with a gray background, the UES logo is placed in the lower right-hand corner, and a main function banner is displayed. The functionbanner is a row of push buttons which appear across the top of the workspace. The number of buttons shown in a function banner and their

INTRODUCTION


capabilities depend upon the specific module which has been activated. When a module is active, with very few exceptions, this row of buttonswill always be visible.

Function banners allow you to move from one capability to anotherwithin the specific module. You select from the banner by positioningthe cursor over the desired push button and clicking the left mousebutton. Each of the push buttons in the function banner result in animmediate action and, depending upon the component of ProCAST, willdisplay either a drop down menu or additional dialog boxes. EachProCAST component is discussed in this manual.

ProCAST allows you to set your own preferences for selected aspectsof your workstation environment. These include background andforeground colors and fonts. These preferences are described inAppendix M -- User Preferences.

Hot Keys In addition to the graphical interface there are several “hot keys” whichhave been implemented in ProCAST. These keys or key combinationsprovide short cuts to commonly performed activities such as zoomingand rotating objects displayed in the work window pane.

The following table summarizes these special keys and the functionsthey perform.

Key, Key Combination,

or Mouse button

Function Performed

F2 Zoom in by 10%

F3 Zoom out by 10%

X Rotate about the x axis by 10%

Y Rotate about the y axis by 10%

Z Rotate about the z axis by 10%

CTRL+X Rotate about the x axis by -10%

CTRL+Y Rotate about the y axis by -10%

CTRL+Z Rotate about the z axis by -10%

SHIFT+X Rotate about the x axis by 30%

SHIFT+Y Rotate about the y axis by 30%

SHIFT+Z Rotate about the z axis by 30%

CTRL+SHIFT+X Rotate about the x axis by -30%

CTRL+SHIFT+Y Rotate about the x axis by -30%

CTRL+SHIFT+Z Rotate about the x axis by -30%

INTRODUCTION

Key, Key Combination,

or Mouse button

Function Performed


SHIFT+LEFT MOUSE

BUTTON

Rotates a rotary toggle switch option list backby one selection

DRAG MIDDLE

MOUSE BUTTON

Drag cursor with the middle mouse buttondepressed, zooms on the area in the drag box

CLICK MIDDLE

MOUSE BUTTON

Repositions the plot: the cursor positionbecomes the center of the display

CLICK RIGHT

MOUSE BUTTON

Zooms out while maintaining current orientation

Manual Organization This manual is organized to provide a reference for each module in theProCAST suite. Accordingly, there is a section dedicated to thePreCAST, DataCAST, ProCAST, PostCAST, and ViewCAST modules. The MeshCAST module is documented in two separate manuals,MeshCAST Users Manual & Technical Reference and MeshCASTTutorial & Exercise Manual. These are available under separate cover.

Technical reference materials, such as mathematical formulations andfile formats have been included in this manual as appendices.

In the following pages, each function, keyword and command isdiscussed in detail. These discussions include descriptions, syntaxoptions, and, in many cases, examples. These discussions have beenwritten in a standard format so that you may quickly find the informationyou need.

The following headings are provided for each topic. In the discussionbelow, the nature of the information presented in each topic isdescribed. The following outline briefly describes the informationpresented for each topic.

Description: The description states what the function, keyword,command, or interface button does.

Method: Method presents a description of how to use the command,feature, or push button. This section discusses all keywords,commands, place holders, optional values, and mandatoryalternative choices. When it is appropriate, the syntax forcommand strings and any required sequence of parameters toenable the function to properly execute is explained.

If the function is a graphical interface object, such as a buttonor menu item, the method section will so state and describe thealternatives and the results to be expected from its activation.

INTRODUCTION


Remarks: Remarks are used to provide a detailed explanation of thesyntax, each parameter in the syntax, the expected results fromthe function or operation, and the impact of specific keyword orparameter combinations.

The level of detail varies depending upon the specificcommand, function or keyword being described. However, at aminimum, Remarks will explain the intent of each parameter,the options available for each parameter, and any casesensitivities.

Remarks are used to provide any special notes, cautions,warnings or tips about the use of the function which may beappropriate.

Related Topics: Related Topics is a keyword-oriented cross referenceto information which may be of relevance. Related Topics is anoptional component of the function write-up.

Example: This component may provide one or more illustrations of howthis function works. Example is an optional component of thefunction write-up.

TypographicConventions

The following typographic and keying conventions are used in thismanual:

Bold Characters or words which appear in a bold typeface

are elements which you must use literally. Theseinclude: key words, function names, commands,

Italic Characters or words which appear in an italic typeface

represent variable values which you must supply.

[brackets] Items which are enclosed by brackets [ ] are optional.

{braces|bars} Characters and/or words which are enclosed by braces{ } and separated by a vertical bar indicate a mandatorychoice between two or more items. You must chooseone of the items unless all of the items are alsoenclosed in brackets.

ENTER Words and characters in SMALL CAPITAL letters are usedto indicate the name of a keyboard key or keysequence.

ALT+F1 A plus (+) sign between key names indicates acombination of keys which you must depress at thesame time. For example, ALT+F1 means to hold down

INTRODUCTION


the ALT KEY while pressing the F1 KEY.

Messages This font (Courier 12cpi) will be used toindicate messages from the software.

Technical Support Additional technical support is available during normal business hours. You contact the UES Technical Support Staff by:

Telephone: 410-573-2037Facsimile: 410-573-2041E-mail: [email protected]

Next Step The recommended next step for using ProCAST and this manual is toread the following topical discussions: Starting ProCAST, DatabaseFacility, Table Maintenance, and Viewing Tools. These topics areincluded in the introduction and provide information about capabilitiesand techniques which have been implemented, where applicable, inProCAST modules.

INTRODUCTION



STARTING PROCAST


STARTING ProCAST

Description ProCAST is available in either UNIX workstation or Windows NTversions. The graphical interface and functionality of each of theProCAST modules is the same in both versions. However, there areslight differences in the method for launching a module based upon theworkstation platform.

Specific methods for launching the ProCAST System (PCS) or one ofits modules will be discussed here. A detailed discussion of anycommand line parameters for specific modules will be discussed in therespective section of this manual which describes that module.

Method There are two basic ways to start ProCAST or one of its modules: 1)typing a command line, or 2) clicking on an icon or menu item. Thesystem’s modular structure allows you to launch individual components,such as PreCAST, PostCAST, ViewCAST, etc., by name or select themfrom a menu on the ProCAST System Interface Screen.

This Interface Screen is shown here. It will be displayed if you type

“procast ” at the NT run or MS-DOS prompt, or type “pcs ” at the Unix

prompt. You may also initiate this screen by clicking on the ProCASTicon in NT Start Menu.

The options available for initiating any ProCAST session aresummarized in a table in the Remarks section of this write-up.

When a ProCAST module is started, you must supply a file prefix. ProCAST uses this prefix to uniquely identify the files associated with aspecific project or problem.

STARTING PROCAST


There are two ways to enter this file prefix; 1) you may type the desiredprefix after the module name in the command line at either a Unix orNT prompt, or 2) you may enter the prefix in a dialog window using thePCS Interface Screen.

At the top of the Interface Screen are two function buttons. The FILEbutton displays a menu which allows you to specify the prefix and theworking directory to be used for this project. This menu is shown here.When you select PREFIX from the menu, a dialog window is displayed.

Type the prefix name in this window and click on APPLY.

When you select DIRECTORY from the menu, a dialog window isdisplayed. Type the directory path and name in this window and clickon APPLY. This dialog window is shown here.

Please note: The DIRECTORY dialog window does not createdirectories; they must be created using the appropriate operatingsystem command prior to running ProCAST.

STARTING PROCAST


After you have provided the prefix name and the directory path, youmay use the EXECUTE button to display a list of the ProCASTmodules. You may select from this list to launch the respectivemodule. The EXECUTE menu is shown here.

The use of the PCS Interface Screen is an optional method for startingProCAST modules. In both Unix and Windows-NT, you may start thedesired module by typing the appropriate information in the promptwindow. Additionally, in Windows-NT you may click on Start, selectRun, and type the appropriate information in the run dialog window.

Remarks The following table summarizes the options for initiating a ProCASTmodule session.

Initiating ProCAST S essions

Windows-NT UNIX

Method Action Method Action

Click on Start,

Select Run,

Type:

procast {prefix} *

and click OK

Opens the PCS

Screen

N/A N/A

Click on the

ProCAST icon on

the NT-Start Menu

or Desktop.

Opens the PCS

Screen

Click on the

ProCAST icon on

the Desktop. **

Opens the PCS

Screen

at the MS-DOS

prompt and press

ENTER.

Opens the PCS

Screen

At the Unix prompt

type:

pcs {prefix} *

and press ENTER.

Opens the PCS

Screen

At the MS-DOS

prompt type:

the module name

{prefix} and press

ENTER. ***

Starts the

respective module.

At the Unix prompt

type:

the module name

{prefix} *

and press

ENTER. ***

Starts the

respective module.

STARTING PROCAST

Initiating ProCAST S essions

Windows-NT UNIX


*Entering the prefix in these commands will place the entered value in the prefix dialog

box.

**Assuming that your Unix release supports this option.

***Options and/or parameters for each module are discussed in eachmodule’s section of this manual.

If you type a ProCAST module name (except MeshCAST) at either theMS-DOS prompt, the NT-Run dialog window, or the Unix prompt and donot provide a prefix name, you will receive a prompt message to entera prefix.

If you are using the NT version, and would like to specify a directory onanother disk, type the following in the directory dialog window:

//x/path/prefixwhere: x = the drive name

path = the path nameprefix = this project’s name

Some modules have unique command line options. These aredescribed, as necessary, in the respective chapter in this manual.

Related Topics Using PreCAST, Using DataCAST, Using ProCAST, Using PostCAST,Using ViewCAST

DATABASE FACILITY


DATABASE FACILITY

Description The Database Facility has been integrated into PreCAST. Access tothe Database Facility is based upon push buttons which appear inselected menus of PreCAST functions and components. For example,when you select MATERIALS, INTERFACES, BOUNDARYCONDITIONS, or RADIATION from the Main Function Banner, a dropdown menu will be displayed. One entry in these menus isDATABASE. Selecting the DATABASE entry from these menus willopen additional Dialog Boxes, Option Lists, Data Input Windows, orsub-menus.

ProCAST’s Database Facility provides a standardized approach formanaging data. Its graphical interface provides guidance in entering,maintaining and managing the data associated with your models. Thenature of the information to be placed in the database depends uponthe property, material, attribute, or intended use of the specific data.

The Database Facility is discussed in this section. Specific options foreach use of the DATABASE will be discussed in more detail in theirrespective sections of this manual.

Method The figure shown here illustrates the menu which is displayed when theMATERIALS function in the MainFunction Banner is activated.

To use the Database Facility click theclick on the DATABASE push button.

The Database Facility is context sensitiveand will display data elements from thedatabase based upon what you are doing

and where you are in PreCAST. Clicking the DATABASE push buttonwill result in the immediate action to display a table containing anyappropriate data elements which may be in the database.

For illustration purposes we will use the DATABASE function in theMATERIALS menu. The figure shown here is a table which contains alist of the materials in the database.

DATABASE FACILITY


Along the top of the table is a group of push buttons which provideaccess to specific database functions. The heading for the table, whichappears below these push buttons and above the table entries, willchange depending upon the database elements being displayed.

When you select a function from this group of push buttons, additionalDialog Boxes, Option Lists, Data Input Windows, or sub-menus will bedisplayed. These graphical interface tools will guide you through theprocess working with information in the database. The syntax for eachof these data elements and any specific input rules will be explained inthe appropriate section of this manual.

The scroll bar at the left side of the table allows you to move throughtable entries, if the number of table entries in the database exceedswhat can be displayed at one time.

Remarks ProCAST provides the capability and flexibility to read, add, copy,modify, or delete data in its databases.

You cannot delete or modify the base set of material data elementswhich come with ProCAST. However, you can copy an entry, renameit, and modify the newly created entry. You may only delete those dataelements which you have added to the database.

The major capabilities of the Database Facility are described here. Specific examples of each type of data element and their respectively

DATABASE FACILITY


required options are provided in the appropriate sections of this manual.

READProvides the capability to read and/or modify detailedinformation about a specific table entry in the database. Youselect the desired table entry by clicking on it. The backgroundof the selected table entry will turn red.

Once a table entry has been selected, click on the READ pushbutton. This will result in the immediate action to retrieve thedata associated with this table entry and display it in anappropriate format. From this display you may be able toselect additional levels of detail for viewing. The figure shownhere illustrates the data which is displayed because we selectedthe IRON_Pure entry in the MATERIALS DATABASE.

As seen in this example, you may view additional detailsassociated with IRON_Pure, by clicking any of the check boxes. Each of these check boxes, in this example, correspond tomaterial properties. The check boxes are shaded according tothe following criteria: if the box is blue, e.g., Conductivity,Density, etc., it indicates that some data has been put in thedatabase for this property. If the box is red it is currentlyselected, and if the box is gray, no data has been put in the

DATABASE FACILITY


database for this property.

If this database entry has your USER name, you may changedata or add data elements to this entry. You may store anydata you may have entered by clicking the STORE push buttonat the bottom of the display. This will store the data in thedatabase and close the display.

You may close the display without storing any data you mayhave entered by clicking the CANCEL push button at thebottom of the display.

ADDProvides the capability to add a data element to the database. You activate the ADD function by clicking the ADD push button. This results in the immediate action to display a blank InputData Box. In this example adding a material would display aninput box like the one shown here.

It is important to note that, in some cases, some input optionsmay not be appropriate or may be mutually exclusive. In thosecases, unavailable option check boxes will be red.

DATABASE FACILITY


You may store any data you may have entered in the InputData Box by clicking the STORE push button at the bottom ofthe box. This will store the data in the database and close theInput Data Box.

You may close the Input Data Box without storing any data youmay have entered by clicking the CANCEL push button at thebottom of the box.

COPYProvides the capability to copy the data associated with onetable entry and rename it. You select the desired table entry byclicking on it. The background of the selected table entry willturn red.

Once a table entry has been selected, click on the COPY pushbutton. This willresult in theimmediate action ofdisplaying a TextInput Box , as shownhere. Type the name

of the new entry in the Text Input Box and press the ENTER key.

This will create the new database entry.

DELETEProvides the capability to delete the data associated with onetable entry. You may only delete an entry from the database ifyou are the one who created it, i.e., it has your USER name. You select the desired table entry by clicking on it. Thebackground of the selected table entry will turn red.

Once a table entry has been selected, click on the DELETEpush button. This will resultin the immediate action todisplay a ConfirmationWindow as shown here. Toconfirm the deletion, click onthe CONFIRM push button. This will delete the databaseentry. This is not reversible after the confirmation. To cancelthe deletion, click on the CANCEL push button. This will cancelthe deletion and close the confirmation window.

Related Topics TABLE MAINTENANCE, MATERIALS, INTERFACES, BOUNDARYCONDITIONS, RADIATION, MICRO, STRESS

TABLE MAINTENANCE


Table Heading(s)

Table Function Push Buttons

Rotary Toggle Switches

Table Entries

TABLE MAINTENANCE

Description Table Maintenance describes ProCAST’s standardized approach forentering data in tables. These table maintenance techniques are usedmost heavily in PreCAST. As discussed in the DATABASE FACILITYsection of this manual, database entries are displayed in a tabular form. You may also use these tabular forms for supplying data for inclusion ina database. Additionally, ProCAST frequently uses a tabular format forcreating lists other than database entries. Specifying Step Values andSpecifying Temperatures in PostCAST’s OPTIONS menu are twoexamples where this Table Maintenance approach is used.

Where Table Maintenance is used, the number of columns in a giventable display will vary depending upon the type of data and its intendeduse. Specific options for each type of data element will be discussed inmore detail in their respective sections of this manual.

Method The figure shown here illustrates a tabular display of the Conductivityproperty for a material. The main parts of the table display are: theTable FunctionPush Buttons,Table Heading(s),Rotary ToggleSwitches, TableEntries, and theEdit Value InputBox.

The number ofcolumns displayedand the presenceof rotary toggleswitches and theirrespective optionalvalues will dependupon the exactnature of the datato be entered andthe valid attributesfor each specificdata element asdefined byProCAST.

TABLE MAINTENANCE


The Table Function Push Buttons may be activated by clicking on thedesired function. These functions accomplish the following activities.

SAVEThis Table Function stores the contents of the table in theappropriate database. If you have added or changed any tableentries, these will be saved at this time.

GRAPHThis Table Function will graph the data points which arecontained in the table entries. There must be at least two rowsfilled out for the function to be graphed. An informationmessage will be displayed if there are an insufficient number ofdata points to plot the graph. If there are no table entries, theGRAPH push button is ignored. The figure shown hereillustrates the graph of the data in the associated table.

ERASEThis Table Function will delete the entire contents of the table. This operation is not reversible.

QUITThis Table Function will result in the immediate action to closethe table display. The data is not stored automatically. Therefore, any data or changes which you have not stored, willbe discarded.

Rotary Toggle Switches allow you to select a value from the list of validentries defined by ProCAST. You select the desired value by clickingthe toggle switch in the table display. This button is a rotary pushbutton. Each consecutive time you click on the button, the next optionin the list is displayed as the label of the button. The valid choices andthe default value, if any, will be described in the appropriate sections ofthis manual. If you change a toggle switch setting, you must use the

TABLE MAINTENANCE


STORE Table Function to retain the change in the database.

Entering data in the table is done by first selecting the desired tableentry. You select a table entry by clicking on it. If the table is empty,select the area in thefirst row under thefirst column heading. This is illustrated inthe figure shownhere.

If the table has dataand you want to addanother dataelement, use thescroll bar, ifnecessary, to moveto the end of thetable and select thefirst empty areaunder the firstcolumn.

Once a table entry is selected the background of that entry will changeto red and the cursor will be placed in the Edit Value Input Box. If theentry contains data, the data will be displayed in the Edit Value InputBox. You may then enter or change the data in the Edit Value Input

Box. When you are satisfied with the new data, press ENTER. This will

place the value in the highlighted table entry and move the cursor to thenext available table entry.

Remarks It is important to note that data elements which are entered or changedin the Table Display are not saved in the database until you use theSTORE Table Function.

Related Topics DATABASE FACILITY, MATERIALS, INTERFACES, BOUNDARYCONDITIONS, RADIATION, MICRO, STRESS

VIEWING TOOLS


Before Center

After Center

VIEWING TOOLS

Description VIEWING TOOLS have been integrated into ProCAST components asa standard set of tools which are available and visible any time there isa geometry displayed in the work window pane. These tools providethe capability to manipulate the geometry in this window. You may usethese tools to facilitate viewing and working with all or part of thegeometry.

Method The figure shown here illustrates the tools available in the VIEWINGTOOLS toolbox. To use a viewing tool,click on it when the cursor is over thedesired function. When you select a tool,ProCAST will perform the designatedfunction or open an additional inputdisplay. You may use these inputdisplays to provide additional instructions

or other directions as to how the selected tool is to be used. Forexample, when you select the ROTATE function, an input display willbe opened to allow you to input the amount and direction of the rotation.

The method, syntax, and use of the Viewing Tools will be discussed inthis section of the manual. For convenience of presentation, they willbe presented in alphabetical order.

CENTER--Use this push button to reposition a point in the geometry tothe center of the work area. The point you pick will be movedto the center of the work window pane. Turn this function on byclicking the left mouse on the CENTER button in the tool box. The button will turn red when it is active. The figure shownhere illustrates this activity. In the figure on the left, the cursoris selecting the point to be “centered”.

The figure on the right shows the geometry as redrawn with the

VIEWING TOOLS


After DragBefore Drag

point we selected in the center of the work window pane.

To reposition the geometry, move the cursor to the point in thewindow you want moved to the center of the work area andclick the left mouse button. Once the geometry has beenredrawn, the background of the push button will return to gray.

CENTER allows you to reposition the geometry into the centerof the work area. You may choose any part of the window to becentered.

CENTER determines the point about which rotations take place. It will redraw the geometry or the portion of the geometry beingdisplayed at the time you click the left mouse button.

DRAG--Use this push button to reposition the geometry to a specificpoint in the work area. Turn this function on by clicking the leftmouse on the DRAG button in the tool box. The button will turnred when it is active. The figure shown here illustrates thisactivity. In figure on the left, the cursor is selecting the point towhich we will “drag” the center of the geometry.

The figure on the right shows the geometry as redrawn with thecenter of the geometry at the point we selected.

DRAG allows you to reposition the geometry by shifting thegeometry to the point you select with the cursor’s position. Thegreen cross will remain in the same position on the model, butyou can move the cross and the model along with it to a newlocation. Once the geometry has been redrawn, thebackground of the push button will return to gray.

DRAG does not have any effect on the geometry. It will redrawthe geometry or the portion of the geometry being displayed atthe time you click the left mouse button.

VIEWING TOOLS


ELEMENTS---Use this push button to display the Element ID Numbersfor each element of the mesh which is in the work window pane. You select this function by clicking the ELEMENTS pushbutton. The element IDs will be drawn in green for eachelement currently being displayed. This is illustrated in the

figure shown here. This display capability does not alter themodel or the mesh. It allows you to focus on specific portionsof the model for analysis.

Using the ELEMENTS tool just after using the HIDDEN tool willlimit the elements labeled to the visible surface elements.

ENCLOSURE--Use this toggle switch to turn on any enclosure elementsfor viewing along with the casting. Normally, you would onlyhave enclosure elements for a view factor radiation model. Turn this function on by clicking the left mouse on theENCLOSURE button in the tool box. The button will turn redwhen it is active. Successive clicks on the ENCLOSUREbutton will toggle the viewing of enclosure elements betweenthe ON and OFF.

HIDDEN--Use this push button to display a hidden surface view of themesh so that only the visible surfaces of the mesh will show. This is particularly useful for verifying the orientation of themodel. Turn this function on by clicking the left mouse on theHIDDEN button in the tool box.

VIEWING TOOLS


MAT SELECT--Use this push button to selectively display portions of

the mesh based upon their material ID. When you select thisfunction by clicking the left mouse button on the MAT SELECTpush button, ProCAST displays a tabular list which contains thematerial IDs and the material names in the model. This list isillustrated in the figure shown here. All of the active materialswill be highlighted with a red background in the list. In thisillustration, the model contains three Material IDs. Only two ofthese materials have been selected as active.

You may activate or deactivate a material by clicking on thedesired row in the list. Successive clicks will toggle betweenthe activated and deactivated.

When you are satisfied with the materials you have selected,click on the QUIT push button. The Material List display willclose and the work area will be redrawn showing only thosematerials you set to be active.

This display capability does not alter the model or the mesh. These capabilities allow you to focus on specific portions of themodel for analysis.

VIEWING TOOLS


NODES--Use this push button to display the Node ID Numbers for eachnode of the mesh which is in the work window pane. You selectthis function by clicking the NODES push button. The nodenumbers will be drawn in red for each node currently beingdisplayed. This is illustrated in the figure shown here. Thisdisplay capability does not alter the model or the mesh. Itallows you to focus on specific portions of the model foranalysis. Using the NODES tool just after using the HIDDENtool will limit the nodes labeled to the visible surface nodes.

RESTORE--Use this push button to restore the geometry to its originalview in the work window pane. Any rotation, node or elementdisplay, zoom or repositioning you may have done whileworking with this geometry will be reset.

Activate this push button by clicking the RESTORE button inthe tool box.

ROTATE--Use this pushbutton to rotate theimage in the workwindow pane. Whenyou click on theROTATE push buttonan input display willbe shown. This is illustrated in the figure shown here.

Select the degree of rotation about each or every axis bymoving the slider in one or more of the horizontal scroll bars. You may move the slider by clicking the left mouse button oneither of the directional arrows, by clicking the left mouse

VIEWING TOOLS


button in the slide track, or by clicking and dragging the slider.

You may specify the direction of rotation by clicking the “+” and“-” toggle buttons. These buttons are located to the right ofeach scroll bar. The maximum amount of rotation, per axis,which may be specified at one time is 180 degrees.

The degree of rotation may be set in each of three scroll barsand in a positive or negative direction. However, the image willnot be rotated until you click on the ROTATE push button.

Selecting the degree of rotation by clicking the directional arrowat either end of the scroll bars will move the slider one degreeat a time. Selecting the degree of rotation by clicking in theslide track will jump the slider. Dragging the slider selects thedegree of rotation in a continuous manner proportionate withthe extent of the mouse movement and the speed at which themouse moves.

Note that the rotation is about the global triad which appears inthe lower left corner of the display screen. The “right-hand” ruleis used.

Click on the ROTATE push button in the control box to havethe image moved after you have set the desired degrees ofrotation.or

Click on RESET to reset all scroll bars to zero and the togglebuttons to “+” without moving the image.or

Click on the QUIT push button in the control box to close thecontrol box without resetting any values you may havespecified or moving the image.

ZOOM--Use this tool to enlarge or shrink the image in the work windowpane. When you clickon the ZOOM pushbutton an inputdisplay will be shown. This is illustrated inthe figure shown here. Select the amount of enlargement or shrinkage by moving theslider in the horizontal scroll bar. You may move the slider byclicking the left mouse button on either of the directionalarrows, by clicking the left mouse button in the slide track, or byclicking and dragging the slider.

Moving the slider toward the “-” shrinks the image; toward the

VIEWING TOOLS


“+” enlarges the image. The maximum range of magnificationor zoom factor is from .01 of the image to 10 times the size ofthe original image. The degree of magnification or shrinkagemay be set in the scroll bar. However, the image will not beadjusted until you click on the ZOOM push button.

Selecting the degree of magnification by clicking the directionalarrow at either end of the scroll bar will move the slider in smallincrements. Selecting the degree of magnification by clickingin the slide track will jump the slider in larger increments. Dragging the slider selects the degree of magnification in acontinuous manner.

Click on the ZOOM push button in the control box to have theimage moved after you have set the desired degree ofmagnification.or

Click on RESET to reset the scroll bar to zero without movingthe image.or

Click on the QUIT push button in the control box to close thecontrol box without resetting any value you may have specified.

Related Topics HOT KEYS

SETTING-UP PROBLEMS

SETTING-UP PROBLEMS, PAGE 2 - 1

CHAPTER 2

SETTING-UP PROBLEMSGeneral Principles When setting up any type of ProCAST analysis, you should keep in

mind the following guidelines:

1. Node and element numbers must be sequential starting from 1. 2. All nodes must be referenced by a least one element. 3. All solid elements must have a material ID. Enclosure elements do

not need a material ID. 4. In general, the denser the mesh, the greater the accuracy of the

results and the longer the cpu time. By judicious selection ofmesh densities, you can often obtain acceptable accuracy withsubstantially less simulation time. Concentrate your elementsin areas of high gradients (temperature or pressure), such as atthe casting walls.

5. It is usually better in terms of accuracy to build the mesh for themold as well as the casting. It is sometimes possible to mimicthe effect of a mold by applying heat flux boundary conditionsdirectly on the casting surface. This can save cpu timebecause of the reduced number of elements. However, it isoften difficult to predict how the mold will behave, especially ifcooling lines are involved, and therefore determining theappropriate boundary conditions is not straightforward.

6. Coincident node interfaces can be automatically constructed byPreCAST where elements with dissimilar material IDs meet. Each coincident interface is uniquely identified by the materialID numbers on either side of the interface. If two materials inyour model meet in several different regions which requirevarying coincident heat transfer characteristics, you must insurethat unique material ID sets will exist at each interface.

7. Multi-point constraints are also automatically generated byPreCAST when nodes of one region lie on the faces ofelements in another region. As in the case of the coincidentnodes, the two regions involved are defined by having differentmaterial ID numbers. Therefore, if two pieces of iron ( havingidentical material properties ) meet in such a way as to requirea multi-point constraint interface, each piece would be given aunique material ID number. In PreCAST, both pieces can beassigned the identical material properties.

8. Multi-point constraints can not be generated across a coincidentnode interface.

9. The effect of a complete die cycle can be captured by placing aheat boundary condition on the coincident node interfacebetween the casting and the mold. Time functions which togglebetween values of 1 and 0 or vice versa can alternately turn onthe interface heat transfer or the boundary heat transfer.

10. You can use the EXTRACT option in PreCAST to take the

SETTING-UP PROBLEMS


temperatures of the mold from the end of one cycle and usethem for the initial temperatures of the next cycle.

11. After running DataCAST, you should always examine theprefixd.out file. Error or warning messages will be written at the

top of this file. DataCAST will convert any quantity units intoCGS units and the results will also be written in this file. Ifsomething looks out of the ordinary may indicate an error indata input. The volumes of each material ID are written, incm3, in the material data summary .

12. Run the problem in ProCAST for 10 time steps. Use thepost-processing features of ViewCAST to see if, thetemperature initial conditions are correct, the temperature dropsacross the coincident interfaces are reasonable, temperaturefields have continuity across the regions where multi-pointconstraints exist, heat fluxes have the right magnitude, andsymmetry faces are experiencing zero flux.

Fluid Flow Analysis Setting up a casting problem for a "fluid and thermal" analysis does notrequire much additional effort as compared to a "thermal only" analysis. The analyst needs only to provide a few additional pieces ofinformation.

Mesh and Material Properties 1. Since no-slip velocity conditions are normally placed everywhere

the metal comes into contact with the mold, each fluid channelshould be at least two elements wide. This would provide onlyone "free" node within the channel, providing only a very coarseestimate of the fluid profile. A channel with at least fourelements across would be more desirable.

2. Wedges, tetrahedrons, and triangles should be used with care influid analyses. All these element types have the potential to beplaced in such a way that all of their nodes lie on the boundary. When this happens, all the nodal velocities are fixed and thepressure in the element becomes indeterminate. These areknown as "dead" elements. Many times these elements have aminimal effect on the analysis. You can usually avoid thissituation by splitting up the meshing volumes such that all theelements have at least one node which is not on the boundary. Using brick or quadrilateral elements will usually eliminate thisconcern.

3. Any material which will be flowing needs to have the properties ofviscosity, liquidus and solidus temperatures specified, inaddition to the usual thermal properties. Not all the materials inthe ProCAST database have this data, so be careful. Viscosity,in particular, is often times hard to come by for alloys. Usingthe viscosity for the corresponding pure base metal is a goodfirst approximation.

SETTING-UP PROBLEMS


Boundary ConditionsIn general, every boundary of the fluid domain requires either a velocityor pressure boundary condition, sometimes both. In most situations,this means that you have to specify the conditions at the inlets andoutlets. The following types of fluid boundary conditions are used inProCAST: 1. No-slip conditions specify a zero velocity on a stationary surface.

PreCAST will automatically put a no-slip boundary condition atall the coincident interface nodes. If the mold walls are notincluded in the model, no-slip boundary conditions should beimposed by specifying a zero u, v, (and w in 3--D) velocities. No time and/or pressure functions are appropriate for this typeof boundary condition.

2. Specified Velocity conditions are used to set non-zero velocityvectors on inflow and outflow. For 2D analyses, both the u andv velocity components must be specified, even if one of them iszero. Likewise, for a 3D analysis, all three velocities must bespecified. These boundary conditions can be given asconstants or can be functions of time and/or pressure.

3. Specified pressure conditions can be used as inflow or outflowconditions or on free surfaces. In some cases it may be used tosimply set a reference pressure. Pressure boundary conditionscan be constant or time varying. ProCAST will automaticallyset the pressure to zero on the free surfaces in the model. Ifthe gas model is utilized, then the pressure on each freesurface will be controlled by the gas model. All models,whether they are free surface or not, should have at least onespecified pressure somewhere in the fluid region. If nospecified pressures are given in a free surface model, thecalculation will be fine until the free surface is forced out of themodel. Once filled, a specified pressure condition is needed.

4. Symmetry conditions force the velocities to align with thesymmetry planes such that the normal components are zero.

5. Periodic conditions link two periodic surfaces together. Pressuresalong the periodic surfaces are equated. The velocities arelinked via the appropriate transformation.

It is important to note that the "natural" boundary condition forthe pressure equation is a zero gradient normal to the wall. This situation promotes a velocity field which runs parallel tothe wall, which is usually desirable. Therefore, in situationswhen the flow does not run parallel to a wall, either a velocity ora pressure boundary condition is required.

Example 1

SETTING-UP PROBLEMS


mold

metal

CL

Filling gate

Top of riser

metal

gas

mold

First, consider an axisymmetric geometry as shown below.

The filling transient is notconsidered in this analysis. Instead, the subsequentcirculation flows are of interest. This analysis can be run one oftwo ways: 1) the free surfacemodel can be used which willinclude the effects of the liquidlevel dropping in the risers, or 2)these effects can be ignored andthe free surface model will not beactuated.

The following fluid boundary conditions are required whether or not thefree surface model is used: 1. u = 0 along the center line (a symmetry condition could be used

just as well). 2. P = 0 along the tops of the risers (if the free surface touches the

top row of nodes, this boundary condition will be needed). 3. u = v = 0 along the coincident interface. This boundary condition

will automatically be included by PreCAST.

The free surface model will work best if there is at least one empty rowof elements at the top of the risers. The initial free surface level can beadjusted using the LVSURF parameter in the prefixp.dat file or in the

RUN PARAMETERS function of PreCAST.

Example 2A simple filling analysis is considered next. In this analysis, the mold isnot included.

The boundary conditions for this modelare as follows: 1. u = u_inlet, v = 0 at the filling gate 2. P = 0 along the top of the riser 3. u = v = 0, everywhere else

It is important to specify no-slip velocitieslast when working in PreCAST. Specifiedvelocities are imposed in sequentialorder. In that way, no-slip velocities willoverwrite inlet velocities at the edges ofthe inlet region, as they should.

Example 3In the next model, a pressurized gas

SETTING-UP PROBLEMS


region is used to drive the metal into the upper mold region.

The analysis is started with the lower melt area already filled. Theboundary conditions for this analysis are: 1. Symmetry condition specified along the left edge of the model. 2. The pressure boundary condition will be governed by the gas

model. If an injection is specified into the gas region above themelt, then the pressure will be mechanistically computed forthat expanding region. The pressure on the metal surfacebeing forced up the sprue will be determined by consideringvents and/or gas porosity within the mold.

3. No-slip boundary conditions will be imposed for the interface byPreCAST. More no-slip boundary conditions are required downin the melt area.

Run ParametersSome of the parameters in the prefixp.dat file need special attention for

a flow analysis. 1. FLOW = 1, turns the flow model on 2. COURANT = 10. to 50. Higher courant limits will allow the use of

larger time steps. However, if excessive restarts are the result,the courant number should be reduced.

3. LVSURF = 0.98 will switch from the filling model to a circulatoryflow model when the metal region is 98% full. If the switch isundesirable, then set LVSURF > 1.0.

4. CONVV = 0.05, sets the velocity convergence to 5 percent. Thiswill require the velocity predictions of the momentum equationsto stabilize to within 5 percent at each time step. Adjusting thisparameter up or down may have a large effect on the allowabletime step.

Radiation Problems The effects of radiation can be handled either by the "simple" method,where you specify an emissivity and an ambient temperature in a heatflux boundary condition, or the more sophisticated view factor method. The comments below are directed towards this latter class of problems. 1. A heat flux boundary condition, containing an emissivity and with

view factors turned on, should be applied to all externalsurfaces of the casting, with the exception of symmetry faces.

2. The view factor radiation model requires a totally enclosed system. Any gaps in the enclosure behave like "black holes" throughwhich energy escapes, yielding unpredictable results. Whenanalyzing a casting with planar or axial symmetry, make surethat the correct angles are being subtended, such that if thesymmetric portion of the enclosure was rotated around, thecasting would be totally surrounded. Also, if the enclosure ismoving relative to the casting or vice versa, make sure that thecasting will not penetrate through the walls during the course ofthe analysis.

SETTING-UP PROBLEMS


3. The walls which comprise the enclosure in a 3D radiation analysismay be modeled with 2D elements, i.e., triangles andquadrilaterals, or by solid elements. Similarly, in a 2D radiationanalysis, the enclosure may be built with either 1D barelements or 2D solid elements.

4. If 2D elements are used to build the enclosure in a 3D problem,make sure that the normal vectors of these elements are facinginward. Also, at a minimum, you need to assign temperaturesand emissivities to these types of elements (and to 1Delements in a 2D problem).

5. If 3D elements are used to build the enclosure, a heat fluxboundary condition, containing an emissivity and with viewfactors turned on, should be applied to all the inwardly directedfaces. Take care not to apply this type of boundary condition,with view factors on, to the outside of a solid elementenclosure.

6. Place your global coordinate system near the geometric center ofyour casting. This will ensure maximum numerical accuracy inthe view factor calculations.

7. Setting RDEBUG to 6 under the RUN PARAMETERS will causeProCAST to produce the prefix.view and prefix.serr files after

the first time step. These can be quite useful in debuggingproblems with the geometry or radiation boundary conditions. These files contain, respectively, face to group view factors androw sum errors. Contour plots of these quantities can beproduced by ViewCAST.

8. If you are modeling one component of a symmetric structure, youcan use ViewCAST to replicate the symmetric parts. Then youcan verify that there are no overlapping regions or gaps presentin your model.

9. Use PostCAST to output a radiation face neutral file, prefixr.ntl.

Use PATRAN or IDEAS to look at this model to verify that thereare no holes in the radiation model.

10. After enough time steps have been computed, check that theenclosure is moving at the right speed. You can see this withViewCAST.

Micromodeling Analysis The ultimate aim of micromodeling is to predict the microstructure ofcastings. The mechanical properties of the castings can then bepredicted from a knowledge of the microstructure. Micromodels can notaccomplish this task alone however. They have to be incorporated intomacromodels to achieve this goal. The coupling of the macro- andmicromodels can be accomplished through the source term in theenergy equation. The rate of evolution of the fraction of solid iscalculated by the micromodels, which controls the release of latentheat.

SETTING-UP PROBLEMS


P

Eutectic Reaction

EA

D

XFe

G

Liquid

Liquid + Graphite

Eutectoid Reaction

Ferrite + Graphite

wt % C

Gamma + Graphite

Liquid + Gamma

Peritectic Reaction

Liquid + DeltaDelta

Delta+

Gamma

Gamma +Ferrite

Ferrite

Gamma

Figure 2-1 Binary Stable Fe - C Phase Diagram

Figure 2-1 illustrates a stable binary Fe-C phase diagram, showingthree types of major reactions: 1. Peritectic Reaction (P) : L + � � 2. Eutectic Reaction (E) : L � � + Gr 3. Eutectoid Reaction (D) : � � � + Gr

Where L symbolizes liquid, � and stand for two differenttypes of body centered cubic (b.c.c.) ferrite, � stands for theface centered cubic (f.c.c.) austenite phase, and Gr stands forgraphite.

Take, for example, a gray iron alloy of carbon equivalent X. Solidification will begin at point G on the phase diagram by formingaustenite dendrites. Austenite dendrites will continue to form until theeutectic temperature, given by the line AE, is reached. At this time, allthe remaining liquid undergoes a transformation by which the liquidsolidifies as austenite and graphite. As the temperature continues todrop, the solute concentration ( i.e., the carbon concentration )decreases following the AD line. When the eutectoid temperaturecorresponding to the point D is reached, the austenite phase transformsinto ferrite and graphite.

Micromodels are activated in ProCAST by choosing a suitable value forthe MICRO parameter in the prefixp.dat file. The following table lists

values for the MICRO parameter corresponding to the differentmicromodels:

SETTING-UP PROBLEMS


MODEL MICRO

Eutectic Ductile Iron 1

Equiaxed Dendrite 2

Coupled Eutectic with Instantaneous Nucleation 4

Coupled Eutectic with Continuous Nucleation 8

Eutectic Gray/White Iron 16

Eutectoid Ductile Iron 32

Gray Iron Eutectoid 64

Peritectic Transformation 128

Solid State Transformations 256

Scheil Model 512

A combination of different micromodels can be chosen in a single runby adding the appropriate MICRO parameters corresponding toindividual micromodels. When you run a PreCAST session and assignthe desired micromodels to the particular material, the MICROparameter is automatically assigned the right value. In our example,the equiaxed dendrite solidification beginning at point G is activated bysetting MICRO to 2. The eutectic transformation at AE is turned on byadding 4 to MICRO, which activates the Coupled Eutectic Model withInstantaneous Nucleation. The MICRO parameter will be automaticallybe assigned a value of 6.

The MFREQ parameter in the prefixp.dat file governs the frequency at

which the relevant microstructural results are stored for restart purposesand for post-processing.

Giving the LINSRC parameter a value of 1 in the prefixp.dat file

switches on linearization of the source term. In this option, a part of thesource term is added to the system matrix, thereby enhancing stability.

Simulating an Al-7% SiAlloy

There is more to running micromodeling analyses than setting theparameters described above. Some material data about the alloy alsohas to be supplied. Suppose that you want to simulate the solidificationof an Al-7%Si alloy in a sand mold. Consider the binary phasediagram, shown in Figure 2-2, for the Al-Si system. For this alloy,equiaxed solidification begins when the liquidus temperature, 618(C, isreached. Equiaxed dendrites continue to grow until the eutectictemperature, 577(C, is reached and eutectic solidification begins.

SETTING-UP PROBLEMS


1.6Si

L

577

wt % Si

Si

1414

Al7 12.6

Al

618

660.5

Figure 2-2 Binary Al - Si Phase Diagram

Note the following aspects of the above phase diagram: 1. Melting point of pure Al = 660.5(C 2. Melting point of pure Si = 1414(C 3. Alloy composition = 7% 4. Eutectic temperature = 577(C 5. Primary transformation temperature = 618(C 6. Liquidus slope, taken as constant = (577--660.5)/12.6 = -

6.63(C/wt% 7. Solute partition coefficient, taken as constant = 1.6 / 12.6 = 0.13

(evaluated at eutectic temperature).

We will model this alloy with a combination of equiaxed dendrite andcoupled eutectic solidification with instantaneous nucleation.

1. In the MATERIALS menu, select MICRO and then press the ADDbutton. Select EQUIAXED DENDRITE..

2. Give the GIBBS---THOMPSON COEFF a value of 2.0e-7 mK. (Kurz and Fisher, Fundamentals of Solidification )

3. ALLOY COMPOSITION = 7.0 4. TRANSF. TEMP = 618(C (assuming that it does not vary with

cooling rate) 5. PARTITION COEFF. = 0.13 6. DIFFUSIVITY = 3.0e-9 m 2/s 7. LIQUIDUS SLOPE = -6.63(C/wt% 8. SUBSTRATE DENSITY: Suppose you obtained from experiment

that the grain size in the castings varies from 0.032 cm to 0.052cm when the corresponding cooling rates vary from 0.2 (C/s to10 (C/s. Using the equation,

SETTING-UP PROBLEMS


43% R 3

L # N 1 (3.4.1)

where RL is the grain size and N is the substratedensity, the following table may be constructed:

Cooling Rate ((C/s) Substrate Density (cm-3)

0.2 1697.86

10 7285.53

9. Click on STORE.10. In the MATERIALS menu, again select MICRO, then ADD. Select

COUPLED EUTECTIC, then INSTANTANEOUSNUCLEATION. We make an assumption of stable eutecticgrowth.

11. STABLE GROWTH CONSTANT = 1.0e-5 cm/sec/K2

12. METASTABLE GROWTH CONSTANT = 4.0e-5 cm/sec/K2

13. SOLVENT MELTING POINT = 660.5 (C14. CRITICAL COOLING RATE = 300 (C/s15. EUTECTIC COMPOSITION = 12.616. TRANSF. TEMP = 577 (C17. PARTITION COEFF. = 0.1318. Let us assume that you obtained the following data from

experiment:

Cooling Rate ((C/s) Substrate Density (cm-3)

0.5 1.0e5

12.2 4.0e5

Here substrate density refers to eutectic cell density, which canbe measured by simple metallographic analysis of themicrostructure.

SETTING-UP PROBLEMS


19. The LAMELLAR SPACING table is arbitrary in this case becausewe already chose to avoid a metastable eutectic structure byintentionally inputting a high value of the CRITICAL COOLINGRATE, i.e., 300 (C/s. However, for the sake of completion, youmay enter following data: Note that with an increase in thecooling rate, the lamellar spacing decreases.

Cooling Rate ((C/s) Lamellar Spacing ()m)

0.3 10

15 2

20. Click on STORE.21. Select MATERIALS, MICRO, and ASSIGN. The two models that

you just put in should appear in the database list. You canassign both of them to the same material ID.

Inverse Modeling Inverse modeling allows you to use the thermal history generated byProCAST as an input for deriving thermophysical properties, initialconditions, or boundary conditions. In order to perform the selectedinverse calculations all other aspects of a problem must be set-up. Thismeans that information about the following components of the problemmust be defined. • geometry, • material properties, • interface heat transfers, • boundary conditions, • initial conditions, and • run parameters.

You may use menu options in the MATERIALS, INTERFACE,BOUNDARY CONDITIONS, and RUN PARAMETERS menus tospecify the component and properties to be calculated using the inversemethodology.

To use the inverse method you should keep the following things inmind: 1. The inverse calculation may be performed for only one material at

a time. If the material to be studied is used in more than onedomain, all corresponding domains will automatically beselected.

2. The inverse calculation for the Interface may be performed inconjunction with the inverse calculation for the BoundaryCondition. It may not be performed in conjunction with theinverse calculation for the material properties.

SETTING-UP PROBLEMS


3. The inverse calculation for the Boundary Condition may beperformed in conjunction with the inverse calculation for theInterface. It may not be performed in conjunction with theinverse calculation for the material properties.

4. The inverse calculation may be performed, at the same time, for allfilm coefficient (H), flux (Q), and emissivity (E) values for oneor more Heat boundary conditions.

5. In a thermophysical calculation, it is possible to determine, at thesame time, specific heat, thermal conductivity, and latent heatproperties. However, you must be careful that these propertiesare not totally independent. The diffusivity is the ratio of thethermal conductivity over the specific heat and the specific heatand the latent heat are both contained in the enthalpy.

6. The inverse calculation will converge much faster if the initial betavalues (i.e., initial guesses) are closest to the final values. Therefore, you are advised to run the direct calculation withProCAST using the initial guess before running the inversecalculation. You should check that the calculated curvesgenerated from the results of the direct calculation are not toofar from the measured curves.

7. If a property is defined as both temperature and time dependant, itis strongly advised not to perform an inverse calculation in thesame time on both the temperature-dependant beta values andthe time-dependant beta values. In this case, it is advisable toperform the inverse calculation with one set of beta valueswhile keeping the others constant and then repeat thecalculation vice-versa.

USING PRECAST

USING PRECAST, PAGE 3 - 1

CHAPTER 3

USING PreCAST

Description PreCAST provides the pre-simulation capability to define the problem. Setting-up the problem is the task of identifying every component of theproblem, defining all of the properties which are relevant to thecomponents of the problem, and associating properties, attributes, andconditions to each component.

Method PreCAST runs in a either a Unix or a Microsoft Windows NT sessionwindow.

PreCAST can be started using the following command line instruction atthe session window prompt or the Run Dialog Window:

precast {prefix} ENTER

Prefix is a required parameter and you should enter the name you wantgiven to this project.

PreCAST may also be started from the EXECUTE menu in the PCSscreen.

Remarks If you start a PreCAST session without the prefix parameter shownabove, you will be prompted to enter a prefix.

Prior to starting PreCAST, you should change the active directory to theone which contains your project.

When PreCAST is activated, it will display a work space with a graybackground, the UES logo in the lower right-hand corner, and a MainFunction Banner across the top of the work space. You may use thepush buttons in this banner to navigate through the functions ofPreCAST.

These functions are:GEOMETRY, MATERIALS, INTERFACE, BOUNDARY, RADIATION, INITIAL CONDITIONS, RUN PARAMETERS, andEXIT

Each of these functions are described in the following pages. They arepresented in the order shown above which corresponds to their left-to-right placement in the Function Banner. This also approximates theorder in which you would ordinarily use the functions of PreCAST.

Related Topics GEOMETRY, MATERIALS, INTERFACE, BOUNDARY CONDITIONS,RADIATION, INITIAL CONDITIONS, RUN PARAMETERS, EXIT

GEOMETRY

GEOMETRY


Description GEOMETRY is a push button in the Main Function Banner. TheGEOMETRY functions of PreCAST enable you to load or create thegeometry of the part(s) or process to be modeled. These functions arealso used to specify attributes of the model. Activating theGEOMETRY push button opens a menu of these geometry and modelattribute functions. Selections from the menu provide capabilities whichwill be discussed in this section.

Method GEOMETRY is activated by clicking on it. The initial menu is shownhere. Please note that the “shaded” options on this initial menu are not

available until after you have specifiedthe UNITS or loaded a RESTART orMESHCAST file. You select otherfunctions from this menu by clicking thedesired function.

The units button on this menu displaysan option list from which you may selectthe units of length which will apply to alldimensions in the model. Afterspecifying the UNITS you may select theappropriate Input File Option.

Once you have specified the units oflength or loaded a RESTART orNEUTRAL file, the initial shading of allmenu options will change to gray. Youmay then select other functions to beperformed.

In most cases, when you select afunction from this menu PreCAST willdisplay additional Dialog Boxes, OptionLists, Data Input Windows, or sub-menus. These graphical interface tools

will guide you through the process of specifying information about yourmodel and the type of analysis to be performed.

The AXISYM and VIRTUAL MOLD functions on this menu are toggleswitches. In the off position the buttons are gray. In the on positionthese buttons are highlighted in burgundy.

GEOMETRY


Remarks Specifying the units of length: You select the

desired units by clicking the UNITS pushbutton in the menu. Clicking this button opensan Option List. Choose the desired units oflength by clicking on the corresponding togglebutton in the option list. When you select aunit of length, the corresponding toggle buttonwill change color and appearance and theOption List will be closed. The choices available in this list are mutuallyexclusive. Selecting a second unit of length will deselect the priorselection. The units selected will be applied to all nodal coordinatesread from the input file and to any points defining symmetry planes oran axis of rotation. The selection of units does not change the sourcedata file.

For RESTART and MESHCAST files, the units of length will be definedin the input file data.

Selecting the input source: PreCAST supports a broad rangeof input file formats. You selectthe input file type by clicking on thetype of file you want. When you select the type of file to be loadedfrom the menu, you will be prompted for the file name. PreCAST willdisplay the file prefix you entered when you started the current sessionof PreCAST. It will also display the appropriate suffix for the file typeyou have chosen. You may accept this information or you may type adifferent file name in the Data Input Window as shown here.

When you are satisfied that the file name you want to load is entered inthe Data Input Window, click on the APPLY push button to load the file

or press ENTER.

You may read more than one input file during a single PreCASTsession by re-selecting an input file format and completing the“Selecting the input source” sequence of actions described above.

You may click on the CANCEL button at any time. This will cancel theData Input Window without loading a file.

GEOMETRY


The input file types and the data types which are supported byPreCAST are described below:RESTART--typically resumes a previous PreCAST job. This option

reads a previously generated prefixd.dat file. If you use the

same prefix, the old prefixd.dat file will be overwritten. File

suffix: d.datMESHCAST--reads a ProCAST/MeshCAST neutral file. The format for

this file is the same as the prefixd.dat file format. File suffix:

d.datPATRAN--reads a PATRAN neutral file. The following data types are

handled: 1 - Node coordinates 2 - Element connectivity and material ID 8 - Nodal displacements (used to indicate pressure/velocity

locations)10 - Nodal temperatures16 - Heat fluxes on element facesFile suffix: .out

IDEAS--reads an IDEAS universal file, Levels 4, 5, 6, and MasterSeries. The following data types are handled:151 - Header15 - Nodal coordinates, single precision781, 2411 - Nodal coordinates, double precision71, 780, 2412 - Element connectivity and material ID164 - Units755 - Nodal temperatures756 - Heat flux on element faces780 - Element connectivity and material ID781 - Nodal coordinates, double precision782 - Heat flux on element facesFile suffix: .unv

ANVIL--reads an ANVIL universal file. The following data types arehandled:NODE - Nodal coordinatesTRIA1 - Linear trianglesQUAD1 - Linear quadrilateralsTETR1 - Linear tetrahedronsPENT1 - Linear wedgesHEXA1 - Linear bricksFile suffix: .out

ANSYS--looks for prefix.ans file and reads ANSYS files 14 and 15.

PreCAST expects to find two files named prefix.14 andprefix.15. These contain element connectivity data and nodal

coordinates, respectively. File suffix: .ans or .14 and .15ARIES--reads element and node information from and ARIES geometry

file. File suffix: .out

GEOMETRY


When you click on the APPLY push button in the dialog box, PreCASTloads the input file and displays information about the status of that filein a message box. The following example shows a message box as aresult of loading a RESTART file.

The message box provides information about: the number of elements,the number of nodes, the number of materials, a summary of theboundary conditions, and if the model contains an enclosure.

When you have read the message box, click on the QUIT push buttonto close this message box.

Related Topics Each menu item shown above is discussed in the following pages.

GEOMETRY


GEOMETRYCREATE 2-D

Description CREATE 2-D is a push button in the GEOMETRY menu. PreCASTprovides the capability to create a geometry and mesh of the part(s) orprocess to be modeled. Clicking on CREATE 2-D opens a simple CAD-type interface. This CAD tool will allow you to draw a geometry andgenerate a mesh for that geometry. This 2-D geometry and mesh maythen be used for further analysis.

Method CREATE 2-D is activated by clicking on it. Selecting CREATE 2-Dresults in the immediate action to open a dialog box requesting you tospecify the minimum and maximum X and Y coordinates for thedrawing area. These values areused for scaling theinput in the drawingarea.

To enter the values,place the cursor inthe appropriate input box and type the desired value. You may move

from one input box to another using the cursor or by pressing the TAB

key.

When you are satisfied with the values you have entered, click on theAPPLY push button. This will apply the constraints to the drawing areaand open the CAD tool.

You may click on the CANCEL button at any time. This will cancel thedialog box and return to the GEOMETRY menu.

Remarks The CAD capability provided in PreCAST consists of a drawing areaand a toolbox. It allows you to create a geometry consisting of straightlines, arcs, and circles and generate a mesh for this geometry. Thetoolbox and its tools are described in the sections of this manual which

are labeled: CREATE 2-D--Toolbox--Tool . Where “Tool” will be

the name of the individual tool such as, LINE, ARC, RESTORE, etc.

GEOMETRY


The general procedure for generating 2-D mesh for analysis consists ofthe following major steps:(1) Create the line drawing. Using the drawing tools in the toolbox to

create the geometry. Each of these tools is discussed in thefollowing sections.

(2) Select the lines which border each region of the model. Uniqueregion identifiers are assigned automatically.

(3) Generate the mesh. In each region of the geometry, you mayspecify a targeted length for the mesh elements. The meshdensity must be uniform within a region of the model. You maychoose either a triangular or quadrilateral mesh for the entiremodel.

(4) Smooth the mesh. Enhance the mesh by using the smooth tooluntil the mesh appears to be smooth.

(5) Quit CREATE 2-D. Press the QUIT push button in the toolbox toexit the 2-D CAD tool. Clicking QUIT before a mesh isgenerated will result in creating the prefix.geom file.

The mesh of triangular or quadrilateral elements of fairly uniform size iscreated within seconds. This allows you to obtain an overallrepresentation of the model and/or set up problems for parametricstudies very quickly.

Related Topics CREATE 2-D--Toolbox and its associated tools.

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox

Description The CREATE 2-D Toolbox is part of the 2-D drawing area which isopened as a result of clicking the APPLY push button after specifyingthe minimum and maximum X and Y coordinates for the drawing areain the CREATE 2-D dialog box.

Some of the tools in the toolbox are push buttons which result in animmediate action such as RESTORE or SMOOTH. Other tools aretoggle switches which enable or disable specific capabilities such asLINE and ARC. Still other tools are push buttons which open a dialogbox to guide you in providing the specific information required tocomplete the selected function. An example of this last group is theMESH push button.

Method Toolbox is displayed and available because you activated the CREATE2-D push button in the GEOMETRY menu. The drawing area and thetoolbox are shown here.You may activate a specific tool by clicking on the desired tool.

To enter values in the coordinate input boxes, place the cursor in theappropriate input box and type the desired value. You may move from

one input box to the other using the cursor or by pressing the TAB key.

The use of these boxes is explained in the discussion of the appropriatetools.

GEOMETRY


If you use the coordinate input boxes, press the ENTER key when you

are satisfied with the values you have entered. This will cause theimmediate execution of the function you have chosen.

Remarks You may click on the QUIT button at any time. This will cancel theCREATE 2-D screen and exit the 2-D CAD tool. Clicking QUIT beforea mesh is generated will result in creating the prefix.geom file.

Related Topics CREATE 2-D--Toolbox--Tools

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--ARC

Description The ARC tool allows you to create a single arc between two points. It isa toggle switch in the CREATE 2-D Toolbox.

Method Select the ARC tool by clicking the ARC push button in the Toolbox.

You may specify the two points by moving the cursor to the desiredlocations in the drawing area and clicking the left mouse button or youmay type the X and Y coordinates in the coordinate input boxes. Youmay also use a combination of these two methods to specify the endsof the arc to be drawn.



Press the ENTER key when you are satisfied with the values you have

entered. This will display the specified point in the drawing area. Repeat the input steps to provide the second point of the arc to bedrawn.

A RADIUS dialog box will be displayed when you have specified thetwo ends of the arc. You must supply theradius of the arc to be drawn and it must begreater than half the distance between thetwo points. Type the radius in the dialog

box and press the ENTER key when you aresatisfied with the value you have entered. The arc will be drawn in the drawing area.

Remarks You may start or end an arc on an existing point in the drawing area bymoving the cursor close to that point and clicking the middle mousebutton.

After the arc has been drawn you may reverse its orientation by clickingthe REVERSE push button in the toolbox.

The ARC function remains active until you select another tool from thetoolbox.

You may delete an arc by using the DEL LINE-ARC tool.

Related Topics DEL LINE-ARC, REVERSE

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--CIRCLE

Description The CIRCLE tool enables you to create a full circle consisting of fourarcs. CIRCLE is a push button in the CREATE 2-D toolbox. It opensan option list which allows you to choose one of two methods forcreating the circle.

Method Activate the CIRCLE function byclicking the CIRCLE push button. Anoption list will be displayed to give you achoice of techniques for defining whereand how the circle will be drawn.

These options are:CENTER-RADIUS--you specify the center point coordinates and the

radius of the circle to be drawn.TWO POINTS--you specify two diametrically opposed points in the

geometry.

In either technique, you may specify the points by moving the cursor tothe desired location in the drawing area and clicking the left mousebutton or you may type the X and Y coordinates in the coordinate inputboxes. You may also use a combination of these two methods.




entered. This will display the specified point in the drawing area. Repeat the input steps, as needed, to provide all required information.

If you choose the CENTER-RADIUSoption, a radius dialog box will bedisplayed. You must supply the radiusof the circle to be drawn.

Type the radius in the dialog box and

press the ENTER key when you aresatisfied with the value you have entered. The circle will be drawn inthe drawing area.

GEOMETRY


Remarks You may attach a circle to an existing point in the drawing area bymoving the cursor close to that point and clicking the middle mousebutton.

The CIRCLE function and the option chosen will remain active until youselect another tool from the toolbox.

You may delete an arc or arcs by using the DEL LINE-ARC tool.

Related Topics ARC, DEL-LINE-ARC

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--DEL LINE-ARC

Description The DEL LINE-ARC tool allows you to delete an existing line or arc. DEL LINE-ARC is a push button in the CREATE 2-D Toolbox.

Method Select the DEL LINE-ARC tool by clicking the DEL LINE-ARC pushbutton in the Toolbox.

Move the cursor to the desired line or arc and click the left mousebutton to highlight the item to be deleted. You may also select the item to bedeleted by sweeping the cursor acrossthe line or arc while holding the mousebutton. A confirmation window will askyou to confirm the deletion. Click on theYES push button in the confirmationwindow to delete the line or arc.

Clicking on the YES push button results in the immediate action todelete the line or arc. Clicking on the NO push button cancels thedelete request.

Remarks Lines or arcs are deleted one at a time. You may select another line orarc for deletion by moving the cursor to that specific line or arc andclicking the left mouse button. The deletion of lines or arcs is notreversible after you confirm the deletion.

The DEL LINE-ARC function remains active until you select anothertool from the toolbox.

Related Topics ARC, LINE

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--DEL REGION

Description The DEL REGION tool allows you to delete the definition of a region inthe model. DEL REGION is a push button in the CREATE 2-D Toolboxwhich opens a table listing all region definitions in the model.

Method Select the region definition to be deleted by clicking on the desireddefinition.

Selecting a region in the table willhighlight the entry with a red background. At the same time, the outline of the regionwill change from cyan to yellow in thedrawing area.

Once the desired region is selected, clickon the DELETE push button in the table tocomplete the deletion process.

You may exit the DEL REGION tool byclicking the QUIT push button in the table.

Remarks Region definitions are deleted one at atime. You may select another regiondefinition for deletion by moving thecursor to that specific line in the table, clicking the left mouse button,and then clicking the DELETE push button. The DEL REGION functionremains active until you click on the QUIT push button in the table.

It is important to note that the lines, arcs, and circles associated with aregion definition are not deleted or physically altered as a result of thisdelete operation. However, they are no longer associated with thisregion definition.

When you create a region after you delete a region, the new region willbe assigned the next sequential number. The old region numbers willnot be reused.

When you need to modify the drawing you must delete all regions. Only after deleting the regions will you be able to modify the geometry.

Related Topics REGION

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--ENCLOSURE

Description The ENCLOSURE tool enables you to specify lines and arcs which willmake up an enclosure rather than solid elements of the model. Anenclosure may be used in a radiation problem where the enclosure mayrepresent the furnace. The enclosure may be assigned specificproperties in other components of PreCAST.

Method Activate the ENCLOSURE function by clicking on it.

The lines and arcs which define the enclosure may be selected bydragging the cursor across them while holding down the left mousebutton. As a line or arc is selected it will change to red. Once a line orarc has been selected release the mouse button. The letter E will bedisplayed at the midpoint of each line/arc in the enclosure.

Continue selecting lines and/or arcs until the enclosure has been fullydescribed.

Remarks The ENCLOSURE function remains active until you select another toolfrom the toolbox. All enclosure selections should be done at the sametime.

An enclosure is used for radiation view calculations.

Related Topics NONE

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--LINE

Description The LINE tool allows you to create a single line or a series of connectedlines. It is a toggle switch in the CREATE 2-D Toolbox.

Method Select the LINE tool by clicking the LINE push button in the Toolbox.

You may specify the two end points for a line by moving the cursor tothe desired locations in the drawing area and clicking the left mousebutton or you may type the X and Y coordinates in the coordinate inputboxes. You may also use a combination of these two methods tospecify the ends of the line to be drawn.




entered. A coordinate point, represented by a small green square, willbe drawn indicating the presence of the line point. Repeat the inputsteps to provide the second point of the line to be drawn.

To draw continuous lines, move the cursor to each desired point andclick the left mouse button.

It is important to note that you must re-select the LINE tool in theToolbox to terminate the continuous lines and allow you to draw anotherline or another set of continuous lines.

Remarks You may start or end a line on an existing point in the drawing area bymoving the cursor close to that point and clicking the middle mousebutton.

You may delete an arc by using the DEL LINE-ARC tool.

Related Topics DEL LINE-ARC

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--MESH

Description MESH is a push button in the CREATE 2-D toolbox. It opens a table ofelement dimensions.

Method Activate the MESH function by clicking theMESH push button. The table of elementdimensions will be opened overlaying aportion of the toolbox. This table will list eachregion of the model. You may specify thetarget length for the mesh elements in aspecific region of the model. If two regionsadjoin each other and have different lengthsfor the mesh elements, the finer mesh densitywill be used along the common edges.

To specify a length value, click on the desiredtable entry. The background of the selectedtable entry will change to red. At the sametime, the corresponding region of the modelwill be highlighted in yellow in the drawingarea.

In the Edit Value input box, type the length you want PreCAST to useas the target length for elements in this region of the model. When you

are satisfied with the value entered, press the ENTER key. This will

update the table entry and the next region in sequence will behighlighted.

When you are satisfied with all table entries, click on the GEN MESHpush button in the table. This will open anoption list which will allow you to choose thetype, triangular or quadrilateral, of mesh whichwill be generated.

Indicate your choice by moving the cursor over the desired mesh typeand click the left mouse button. This will result in the immediategeneration of the mesh.

GEOMETRY


Remarks Clicking on QUIT before a mesh is generated will result in creating theprefix.geom file.

The time required to create the mesh depends on the element sizerelative to the region, but is normally finished within a minute. Whilethe mesh is being generated, PreCAST displays a progress meter in thelower portion of the drawing area.

When the mesh has been generated it will be displayed in the drawingarea, as shown here.

Note the two densities of mesh which were generated. These werebased upon the values in the table as described above.

CREATE 2-D can not generate any higher order mesh elements suchas quadratic.

Related Topics

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--MOVE

Description The MOVE tool allows you to move an existing point in the drawingarea. MOVE is a toggle button in the CREATE 2-D Toolbox. Linesconnected to the point which is moved will also be moved to maintaintheir contact with the selected point.

Method Activate the MOVE function by clicking the MOVE push button. Thecursor icon will change to resemble a small bulls eye.

Move the cursor to the point you want to move and click either the leftor the middle mouse button. Move the cursor to the desired newlocation and click the left or middle mouse button again.

Remarks The MOVE function remains active until you select another tool fromthe toolbox.

MOVE will not work on points which are connected to arcs or pointswhich have been assigned to regions.

Related Topics LINE, ARC

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--QUIT

Description QUIT closes the CREATE 2-D drawing area and toolbox.QUIT is a pushbutton in the CREATE 2-D toolbox and results in an immediate action.

Method Activate QUIT by clicking on it.

Remarks If you press QUIT before a mesh has been generated it will be saved ina prefix.geom file.

Clicking QUIT before a mesh is generated will result in creating theprefix.geom file. The CREATE 2-D drawing area will be closed and the

meshed geometry will be displayed in the work window pane.

Related Topics MESH

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--REGION

Description The REGION tool enables you to assign lines and arcs to specificregions of the model. These lines and arcs define the boundaries of aregion. A region may be assigned a specific material ID and otherproperties in other components of PreCAST.

Method Activate the REGION function by clicking the REGION push button.

The lines and arcs which form the border of the region may be selectedby dragging the cursor across them while holding down the left mousebutton. As a line or arc is selected it will change to red. Once a line orarc has been selected release the mouse button. You may select linesand arcs which make up internal boundaries in the same manner.

Remarks Continue selecting lines and/or arcs until the region has been fullyenclosed. At that time, a region number will be automatically assigned. These numbers will be displayed at the midpoint of each line/arc in theregion. You should include any inner borders of a region in thatregion’s selection. For example, if you were modeling a donut in 2-D,the region of the donut would include the arcs forming the outside of thedonut and the arcs forming the outside of the donut hole.

Click on the REGION push button again to select lines and arcs to beassigned to another region. Individual lines or arcs may be associatedwith more than one region.

Related Topics DEL REGION

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--RESTORE

Description The RESTORE tool reads a 2-D geometry which has previously beensaved as a prefix.geom file. RESTORE is a push button in the

CREATE 2-D Toolbox which results in the immediate operation to readthe prefix.geom file and display the geometry in the drawing area.

Method Activate the RESTORE function by clicking on it. You may use anyarbitrary numbers to define the workspace. The model willautomatically scale the work area.

Remarks Prefix.geom files are created when you select the MESH tool or when

you QUIT CREATE 2-D.

Related Topics MESH, QUIT

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--REVERSE

Description The REVERSE tool allows you to switch the orientation of the last arccreated. As a result of the REVERSE tool’s action a concave arc canbe made convex and vice versa. REVERSE is a toggle switch in theCREATE 2-D Toolbox.

Method Select the REVERSE tool by clicking the REVERSE push button in theToolbox.

Clicking the REVERSE push button results in the immediate action tochange the orientation of the arc.

Remarks Clicking the REVERSE push button again will change the arc’sorientation back to its original position.

You may click on the REVERSE push button at any time, however, itwill always change the orientation of the last arc you have drawn.

Related Topics ARC

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--SPLIT

Description The SPLIT tool enables you to create a new point at the intersection oftwo lines or arcs. SPLIT is a push button in the CREATE 2-D toolbox.

Method Activate the SPLIT function by clicking the SPLIT push button.

Move the cursor across the desired intersection while holding down theleft mouse button. The two lines to be selected will change to yellowwhen they have been selected.

Release the mouse button and the new point will appear.

Remarks You may split a line or arc in order to be able to remove either of theresulting segments.

The SPLIT function remains active until you select another tool fromthe toolbox.

Related Topics ARC, LINE, DEL LINE-ARC

GEOMETRY


GEOMETRYCREATE 2-D--Toolbox--SMOOTH

Description The SMOOTH tool enables you to improve the quality of the mesh. SMOOTH is a push button in the CREATE 2-D toolbox.

Method Activate the SMOOTH function by clicking the SMOOTH push button. This results in the immediate action of improving the quality of themesh.

The improved mesh will be displayed in the drawing area.

Remarks SMOOTH improves the shape of the triangular or quadrilateralelements in the mesh by adjusting the nodal locations. Each node isplaced at the center of the nodes immediately surrounding it.

The SMOOTH push button may be pressed several times until noadjustment is detectable in the drawing area.

Related Topics MESH

GEOMETRY


GEOMETRYSYMMETRY

Description SYMMETRY is a push button in the GEOMETRY menu. PreCASTprovides the capability to specify rotational and/or mirror symmetry forradiation problems. SYMMETRY opens an option list sub-menu whichallows you to specify the symmetry properties for your model.

Method Activate SYMMETRY by clicking theSYMMETRY push button. This results in animmediate action to open the sub-menushown here.

The method and syntax for each of theseoptions will be described below. Each onemay be activated by clicking the left mousebutton when the cursor is over the respectivepush button.

ROTATIONAL--specifies a symmetry in which a base object isrepeated, at evenly spaced intervals, around an axis of rotation. Activating the ROTATIONAL option will open a dialog box asshown.

In this dialog box you specify:SECTORS--specifies the number of times the base object is to

be repeated around the axis of rotation.Enter an integer value.

COORDINATES0 --one of two sets of coordinates which definethe axis of rotation.

COORDINATES1 --one of two sets of coordinates which definethe axis of rotation.

When you are satisfied with the values entered in the dialogbox, click on the APPLY push button.

You may click on the CANCEL push button at any time tocancel this operation without setting or changing any values.

GEOMETRY


MIRROR 1--specifies a symmetry in which a plane of symmetry is usedto create a mirror image about the specified plane. Activatingthe MIRROR 1 option will open a dialog box as shown.

In this dialog box you specify the coordinates of the three pointsrequired to define a plane:COORDINATES0 --one of three sets of coordinates which

define the plane of symmetry.

COORDINATES1 --one of three sets of coordinates whichdefine the plane of symmetry.

COORDINATES2 --one of three sets of coordinates whichdefine the plane of symmetry.

When you are satisfied with the values entered in the dialogbox, click on the APPLY push button.

You may click on the CANCEL push button at any time tocancel this operation without setting or changing any values.

MIRROR 2--works in the same way as MIRROR 1 and allows you tocreate two planes of mirror symmetry in the same problem.

EXECUTE--finds faces on the model which lie on the planes ofsymmetry and includes them in a symmetry boundary conditionset.

QUIT--closes the option list box.

Remarks You may have one rotational symmetry and two planes of mirrorsymmetry in the same problem. If there is only one plane of symmetry,then you should input the data in MIRROR 1.

The symmetry properties are used for creating virtual images of anobject which will take part in the view factor calculations.

Related Topics

GEOMETRY


GEOMETRYGRAVITY

Description GRAVITY is a push button in the GEOMETRY menu. PreCASTprovides the capability to specify the direction of gravitational pull onthe model. GRAVITY opens a dialog box which allows you to specifythe direction and units of measure for the gravitational factors affectingyour analysis. This is used in fluids and stress simulation problems.

Method Activate the GRAVITY function by clicking the GRAVITY push button. This results in an immediate action displaying the dialog box shownhere.

The dialog box also containspush buttons which may beused to activate additionalgravity-related functions. Themethod and syntax for each ofthese functions and inputoptions will be describedbelow. Each one may be activated by clicking the left mouse buttonwhen the cursor is over the respective push button.

X, Y and Z--are the components of the gravitational vector. To enterthe values, place the cursor in the appropriate input box andtype the desired value. You may move from one input box to

another using the cursor or by pressing the TAB key.

For example, in SI units, gravitational acceleration at theearth’s surface is 9.8 meters/second2 in the downward direction. If the Z axis in your model is pointing up, you would enter -9.8for the Z component and leave the X and Y components at 0.0.

The default values for these components, in a 2-D problem are:X = 0.0, Y = -9.8, and Z = 0.0. The default values in a 3-Dproblem depend upon the model.

If the direction of gravity is at an angle, you must manuallycalculate the x, y, and z component of the gravitational force.

GEOMETRY


UNITS--specifies the units of gravitational acceleration to be used forthis analysis. This push button is a rotary toggle switch. Clicking on the UNITS toggle switch will cycle through theoptional units of acceleration. Your choices are:{m/sec**2|cm/sec**2|mm/sec**2|ft/sec**2|in/sec**2}.

The default is m/sec**2.

When you are satisfied with the values you have entered, clickon the APPLY push button.

ROTATE--enables you to specify an axis of rotation and the angle ofrotation as a function of time. Activating the ROTATE optionwill open the dialog boxes shown below.

AXIS OF ROTATION--use the dialog box to specify:COORDINATES0 --one of two sets of coordinates which

define the axis of rotation.COORDINATES1 --one of two sets of coordinates which

define the axis of rotation.

ANGLE VERSUS TIME FUNCTION--is defined in a dialog boxwhich is a two column table. In column one (Time) youspecify the elapsed time. In column two (Theta) youspecify the corresponding amount of rotation indegrees.

At the top of column one in the table is a rotary togglebutton which may be used to set the units of time forthe table. Your choices for this unit of time are:{sec|min}. Successive clicks on this push button will

toggle between these two units. The default is sec .

GEOMETRY


To enter values in the table:(1) move the cursor to a position to the right of the

number one,(2) click on the left mouse button. The first row and

column space will be highlighted in red.(3) move the cursor to the Edit Value input box at the

bottom of the table,(4) enter the desired value,

(5) press ENTER. The entered value will be placed in

the table and the cursor will automatically bemoved to the next available column and rowentry.

(6) Continue entering data as necessary by repeatingsteps 4 and 5. You should have a minimum oftwo table entries.

To change values in a table entry:(1)(1) move the cursor to the table entry to be changed,(2) click on the left mouse button. The table entry will

be highlighted in red and its value will bedisplayed in the Edit Value input box.

(3) move the cursor to the Edit Value input box at thebottom of the table,

(4) enter the desired value,

(5) press ENTER. The entered value will be placed in

the table and the cursor will automatically bemoved to the next available column and rowentry.

SAVE--When you are satisfied with the values entered in thetable, click on the SAVE push button at the top of thetable. This results in the immediate action to save theAngle Versus Time Function table.

GEOMETRY


GRAPH--This push button results in the immediate action todisplay a graph of the values in the Angle Versus TimeFunction table. The following example is based upontable data which was created for convenience ofillustration.

ERASE--this push button results in the immediate action toerase the entire contents of the Angle Versus TimeFunction Table.

QUIT--this push button results in closing the Angle Versus TimeFunction dialog box. The dialog boxes are closedwithout saving any data which may have been enteredor changed.

If you want to retain the data in the table, be sure toclick on the SAVE push button prior to using QUIT.

CANCEL--You may click on the CANCEL push button at any time toclose the GRAVITY function dialog boxes. This CANCELoperation does not save or store any values.

APPLY--when you are satisfied with the values entered in the dialogboxes, click on the APPLY push button. This results in theimmediate action to save the values you entered as a part ofthis analysis.

Remarks The ROTATE capability of GRAVITY is typically used for tilt pouringoperations.

Related Topics

GEOMETRY


GEOMETRYCENTRIFUGAL

Description CENTRIFUGAL is a push button in the GEOMETRY menu. It opens adialog box which allows you to specify an axis of rotation and anangular velocity for your analysis. This is used in centrifugal castingprocess problems.

Method Activate the CENTRIFUGAL function by clicking the CENTRIFUGALpush button. This results in an immediate action to open the dialog boxand control panel shown here.

The control panelcontains push buttonswhich may be used tospecify angularvelocity. The methodand syntax for each ofthese functions andinput options will bedescribed below. Each one may beactivated by clicking the left mouse button when the cursor is over therespective push button.

In the dialog box, you enter the coordinates which describe the axis ofrotation.COORDINATES0 --one of two sets of coordinates which define the axis

of rotation.

COORDINATES1 --one of two sets of coordinates which define the axisof rotation.

To enter the values, place the cursor in the appropriate inputbox and type the desired value. You may move from one input

box to another using the cursor or by pressing the TAB key.

GEOMETRY


CONSTANT--specifies a constant rate of rotation about the axis ofrotation. This push button opens a dialog box which allows youto enter the constant and selectthe time interval units. Enter theconstant rate of rotation inradians.

At the top right-hand corner of the dialog box is a rotary togglebutton which may be used to set the time interval units. Yourchoices for this unit of time are: {1/sec|1/min}. Successiveclicks on this push button will toggle between these two values.

The default is 1/sec .

TIME--enables you to specify an angular velocity which is a function oftime. When you click on the TIME push button a table willopen. You use this table to specify the time and angularvelocities for your analysis.

At the top of column one of this two-column table is a rotarytoggle button which may be used to set the units of time for thetable. Your choices for thisunit of time are: {sec|min}. Successive clicks on thispush button will togglebetween these two units.

The default is sec .

At the top of column two is arotary toggle button whichmay be used to set the unitsof time angular velocity forthe table. Your choices forthis unit of time are:{1/sec|1/min}. Successiveclicks on this push button will toggle between these two values.

The default is 1/sec .

In column one you specify the elapsed time. In column two youspecify the corresponding angular velocity in radians.

To enter values in the table:(1) move the cursor to a position to the right of the number one,(2) click on the left mouse button. The first row and column

space will be highlighted in red.(3) move the cursor to the Edit Value input box at the bottom of

the table,(4) enter the desired value,

GEOMETRY


(5) press ENTER. The entered value will be placed in the table

and the cursor will automatically be moved to the nextavailable column and row entry.

(6) Continue entering data as necessary by repeating steps 4and 5. You must have at least two table entries.

To change values in a table entry:(1)(1) move the cursor to the table entry to be changed,(2) click on the left mouse button. The table entry will be

highlighted in red and its value will be displayed in theEdit Value input box.

(3) move the cursor to the Edit Value input box at the bottom ofthe table,

(4) enter the desired value,

(5) press ENTER. The entered value will be placed in the table

and the cursor will automatically be moved to the nextavailable column and row entry.

SAVE--When you are satisfied with the values entered in thetable, click on the SAVE push button at the top of thetable. This results in the immediate action to save thetable.

GRAPH--This push button results in the immediate action todisplay a graph of the values in the table. Thefollowing example is based upon table data which wascreated for convenience of illustration.

ERASE--this push button results in the immediate action toerase the entire contents of the table.

GEOMETRY


QUIT--this push button results in closing the Time and AngularVelocity dialog boxes. The dialog boxes are closedwithout saving any data which may have been enteredor changed.

If you want to retain the data in the table, be sure toclick on the SAVE push button prior to using QUIT.

CANCEL--You may click on the CANCEL push button at any time toclose the GRAVITY function dialog boxes. This CANCELoperation does not save or store any values.

APPLY--when you are satisfied with the values entered in the dialogboxes, click on the APPLY push button. This results in theimmediate action to save the values you entered as a part ofthis analysis.

Remarks ProCAST multiplies the CONSTANT value supplied times the Tabularentries in the TIME/VELOCITY table, if any, to determine the angularvelocity.

Related Topics

GEOMETRY


GEOMETRYCHECK GEOM

Description CHECK GEOM is a push button in the GEOMETRY menu. CHECKGEOM opens an option list sub-menu. PreCAST provides thecapability to verify that all mesh elements have positive Jacobians, thatall surface elements have positive surface areas, and that all enclosureelements have normals with the proper orientation. These checks areimportant to further successful analysis of your model.

Method Activate the CHECK GEOM function by clicking the CHECK GEOMpush button. This results in an immediateaction to open the option list sub-menushown here.

The option list provides the capability toexamine specific aspects of your model.The option list is a series of push buttonscorresponding to the type of check whichwill be performed. The method andsyntax for each of these options will bedescribed below. Each one may be activated by clicking the left mousebutton when the cursor is over the respective push button.

NEG--JAC: checks the model to makesure that all elements in themodel have positive Jacobians. Elements with negative Jacobianvalues are identified in a list. Thelist is displayed on the right sideof the work window pane. Anexample of the list is shown here. To display negative Jacobianelements graphically in the workwindow pane, select an elementnumber and click on the SHOWELEMENT push button.

NEG-AREA: checks the model to makesure that all surface elements inthe model have positive surfaceareas. Elements with negative areas are identified in a list. The list is displayed on the right side of the work window paneand the negative surface areas are displayed graphically in thework window pane. The list will be similar to the one shownabove for NEG-JAC elements. This test is only significant forradiation models. View factors cannot be calculated for faces

GEOMETRY


These arrows indicate the direction ofthe enclosure’s normals.

Tools for manipulating the orientationof the enclosure’s normals.

that fail this test.

ENCLOSURE: checks the model to make sure that all of the enclosureelements have normals with the proper orientation. Normalorientation of all the enclosure elements is displayedgraphically in the work window pane. Additionally, five tools will

be displayed in the right margin. These tools allow you toselect specific enclosure elements and change the direction oftheir normals. These tools are shown here and explained in thefollowing paragraphs.

GEOMETRY


SELECT: allows you to select individual elements formanipulation. To activate this tool, click on theSELECT push button. You may then choose theelement(s) by placing the cursor over them and

selecting them by pressing the left mouse button or youmay drag a selection box by pressing the right mousebutton and enclosing the desired elements.

When the elements have been selected they willchange color to red. In the example shown here,elements have been selected.

DESELECT: allows you to deselect individual elements formanipulation. To activate this tool, click on theDESELECT push button. You may then choose theelement(s) by placing the cursor over them andsnagging them while pressing the left mouse button oryou may drag a selection box by pressing the rightmouse button and enclosing the desired elements.

When the elements have been deselected they willchange color to white.

SELECT ALL: allows you to select all elements formanipulation. To activate this tool, click on theSELECT ALL push button. When the elements havebeen selected they will change color to red.

GEOMETRY


CANCEL: allows you to close the enclosure display. Toactivate this option, click on the CANCEL push button. This will result in the immediate action to close theenclosure display.

REVERSE: allows you to reverse the direction of the normalsfor the selected elements. To activate this tool, click on

the REVERSE push button. This will result in theimmediate action to change the direction of all and onlythe elements which have been selected. Forconvenience of illustration, in the figure shown here,three elements have had the direction of their normalsreversed.

GEOMETRY


VOLUMES: calculates the volume ofeach material region. Thecalculation will be in cubiccentimeters. These materialvolumes will be displayed in atable at the right-side of the workwindow pane. An example of thetable of material volumes isshown here.

Remarks These diagnostic tools should be used to evaluate the quality of thegeometry and mesh. The quality of the geometry and mesh have adirect bearing upon the eventual outcome of the simulation.

Related Topics

GEOMETRY


GEOMETRYAXISYM

Description AXISYM is a toggle button in the GEOMETRY menu. AXISYM allowsyou to specify the Y axis as the axis of symmetry. PreCAST providesthe capability to model 2-D axisymmetric problems.

Method Activate the AXISYM toggle button by clicking the AXISYM push button. This results in an immediate action to change the color of the statusbox.

Subsequent clicks on the AXISYM push button will toggle betweenturning axisymmetry on and off.

Remarks When AXISYM is toggled to the “on” position, the Y axis is always takenas an axis of symmetry and the X axis will point in the positive radialdirection.

You must have your model aligned at X = 0 for AXISYM to work.

Related Topics

GEOMETRY


GEOMETRYVIRTUAL MOLD

Description VIRTUAL MOLD is a push button in the GEOMETRY menu. PreCASTprovides the capability to simulate a mold around the casting withoutcreating a geometry for the mold. This allows you to analyze the heatconduction around the casting by mimicking the effect of a real mold.

Method Activate the VIRTUALMOLD function byclicking the VIRTUALMOLD push button. This results in animmediate action toopen a dialog boxwhich enables you to

enter the minimum and maximum coordinates of the mold. The colorof the status box will also change.

As shown here, the dialog box consists of input lines where you mayspecify the minimum and maximum values for each of the x, y, and zcoordinates of the mold.

The dialog box also contains three push buttons which perform thespecific actions described below. Each one may be activated byclicking the respective push button.

APPLY: applies the minimum and maximum values entered, createsthe virtual mold, and closes the dialog box.

REMOVE: removes the coordinate values entered and closes thedialog box. It also removes the virtual mold if it has beencreated.

CANCEL: closes the dialog box.

GEOMETRY


Remarks VIRTUAL MOLD applies an analytical heatconduction solution around the casting which mimicsthe effect of a real mold. When minimum andmaximum coordinates have been specified andapplied, Pro-CAST computes a penetration depth foreach face of the casting that is within the “virtual”box.

VIRTUAL MOLD adds a new material ID to themodel. You may assign mold properties to this newmaterial ID. Using the Interface component ofProCAST, you may create and assign interface heattransfer coefficients between the external faces ofthe casting and the virtual mold.

The color legend, as shown in this figure, graphicallyrepresents the resulting thermal depth or penetrationdepths between the virtual mold and the casting.

Related Topics INTERFACE

MATERIALS


MATERIALS

Description MATERIALS is a push button in the Main Function Banner. Thisfunction of PreCAST enables you to add materials and your ownmaterial properties to the database. It also enables you to assignspecific materials to the model. When you activate the MATERIALSpush button, a menu is opened which will allow you to work with specificproperties for each material in the database. Selections from the menuprovide capabilities which will be discussed in this section.

Method MATERIALS is activated by clicking on it. The initial menu is shownhere. When you select a function fromthis menu PreCAST will displayadditional Dialog Boxes, Option Lists,Data Input Windows, or sub-menus. These graphical interface tools will guideyou through the process of specifying,changing or deleting information aboutthe materials in the database.

You may leave the MATERIALS functionby clicking another push button in the Main Function Banner.

Remarks ProCAST provides the capability and flexibility to add, delete, or modifya material in the material database. If you intend to use the materialdata that comes with ProCAST, as is, you can proceed to the ASSIGNfunction.

The major capabilities of the MATERIALS function of PreCAST will besummarized here. Each capability will be described in greater detail inthis manual.DATABASE

Provides the data management functions for the materials andtheir respective properties in your database. DATABASE allowsyou to add, delete, copy, and modify entries in the materialsdatabase.

ASSIGNProvides the capability to assign material properties toelements in the model.

STRESSProvides the data management and assign functions for stressmodeling material properties. Allows you to define amechanical model for the material.

MICRO

MATERIALS


Provides the data management and assign functions for micromodeling material properties.

INVERSEInverse modeling will calculate selected material properties byusing the numerically generated thermal history and measuredtemperatures. The inverse solver calculates the optimummaterial property which will give the best match between themeasured and calculated cooling curves for the material. Theproperties which may be determined using inverse modelingare: Heat capacity, Thermal conductivity, and Latent heat.

When you select the STRESS or MICRO capabilities, another sub-menu will be displayed. From this sub-menu you may select theDATABASE or ASSIGN functions relating to either the stress or microproperties of the material.

ProCAST’s graphical user interface provides a straight forward andsimple procedure for working with the various databases used byProCAST. This database facility is described elsewhere in this manual. You should read about this facility before attempting to modify thematerials database.

Related Topics DATABASE FACILITY, REGION

MATERIALS


MATERIALSDATABASE

Description DATABASE is a push button in the MATERIALS menu which accessesthe Materials Database. Using ProCAST’s DATABASE FACILITY youmay create, delete, or modify a material or its properties in thematerials database. These materials may then be used for simulationand analysis.

Method DATABASE is activated by clicking on it. This results in the immediateaction to display a table containing any materials which may be in thedatabase. The figure shown here illustrates a display of the materials inthe MaterialDatabase.

PreCAST allows youto Read, Add, Copy,and Delete materialsfrom the MaterialsDatabase. Thesecapabilities aredescribed in theDATABASEFACILITY section ofthis manual. Youshould also refer tothe TABLEMAINTENANCEsection of thismanual whichdescribes ProCAST’sgraphical interface for maintaining tables.

This section will discuss the requirements for adding a material to thedatabase and how you specify individual properties and attributes forthat material.

To add a material to the database, click on the ADD push button in theMaterial Database display. This will result in the immediate action toopen a blank Material Description which is shown below. Note thatPreCAST has entered the USER name and the DATE for you.

MATERIALS


The minimum requirement for adding a material to the database is togive it a name and specify properties for the material. Individualproperties which may be required depend upon the type of modelingand analysis to be done.

The syntax and options available for the Material Definition arediscussed below.

MATERIAL NAME: Enter the name you want to give the new material. The material name must begin with an alphabetic character and mayinclude upper and lower case characters.

BASE: ProCAST will calculate material properties based upon thematerial database which is supplied with it. To enter a base material,place the cursor in the BASE input box and type one of the materialtypes supplied. You may choose from [ Al | Ni | Ti | Fe]. When youhave typed the base material to be used, click on the COMPOSITIONpush button.

MATERIALS


COMPOSITION: This push button allows you to specify the alloycomposition to have ProCAST calculate the material properties. Asshown below, when you select this push button, a composition table willbe displayed. In this table you may enter the components of the alloyand their weight percentage of the total alloy.

To enter the components of the alloy, place the cursor in the firstavailable input space in column one and type the element’s symbol. Then place the cursor in the column two input space adjacent to theelement and type the percentage of this element which is in thecompound. You may repeat this process for additional elements. Youmay change an alloy or its corresponding percentage by placing thecursor in the desired input line and re-typing the desired value.

When you are satisfied with the composition, click on the APPLY pushbutton. The composition will be highlighted as a reminder that data hasbeen entered.

You may close the composition table, without specifying the alloycomposition, by clicking the CANCEL push button. In the input boxlabeled BASE, enter the base element of the alloy.

MATERIALS


PROPERTIES:Properties are shown in four categories: THERMAL, FLUID, FILTER,and ELECTROMAGNETIC. The properties which may be chosenwithin each category are displayed as a group of check boxes or pushbuttons. To specify a property, click the left mouse button when thecursor is over the desired property’s check box. Selecting a property inthis manner will result in the immediate action to display an additionaldialog box or data input table.

Some properties may be described only as a constant value whileothers may be described as a constant, a linear function or a quadraticfunction. Based upon the individual property you select, ProCAST willdisplay the appropriate dialog or input table.

The simplest of these input boxes is similar to the one shown here andmay contain a rotary toggle switch for the units of measure and a textinput line. Select thedesired units ofmeasure by clickingon the UNITS pushbutton. Successiveclicks on this pushbutton will toggle through the available options. To enter the desiredvalue for this property or attribute move the cursor to the text input lineand type the value. When you click on the APPLY push button, thedata entered will be stored, the dialog box will be closed, and theproperty’s check box on the Material Definition display will behighlighted in light blue.

You may click on the CANCEL push button to close the dialog boxwithout saving the data.

For those properties which may also be described as linear or quadraticfunctions, ProCAST willdisplay an option box fromwhich you may choose to usea CONSTANT, LINEAR, orQUADRATIC function. An example of this option box is shown here.

Selecting the CONSTANT option will display a dialog box similar to theone described in the preceding paragraphs.

Selecting the LINEAR option will result in the immediate action todisplay an input table. This table, like the dialog box for a constant,may contain rotary toggle switches for the units of measure. As shownin this example for Conductivity, there are two toggle switches whichalso serve as the column sub-headings for the table.

MATERIALS


Rotary ToggleSwitches

Select the desired units of measure by clicking on the column headingpush buttons. Successive clicks on these push buttons will togglethrough the availableoptions. To enter atable value, selectthe first or nextavailable table entry,move the cursor tothe text input line,type the value, and

press the ENTER key.

This will place thevalue in the table andmove the cursor tothe next availabletable entry. Whenyou are satisfied withthe table entries, clickon the STORE pushbutton, the data inthe table will bestored, the dialog boxwill be closed, andthe property’s check box on the Material Definition display will behighlighted in light blue.

You may click on the GRAPH push button to display a graph of thefunction. You may click on the ERASE push button to erase the entirecontents of the table. You may click on the CANCEL push button toclose the dialog box without saving the data.

Selecting theQUADRATIC optionwill result in theimmediate action todisplay an inputtable. In this table,column sub-headingsmay act like therotary toggle switchesfor the units ofmeasure. As shownin the followingexample, there aretwo column sub-heading toggleswitches.Select the desired

MATERIALS


units of measure by clicking on the column sub-heading push buttons. Successive clicks on these push buttons will toggle through theavailable options. To enter a table value, select the first or nextavailable table entry, move the cursor to the text input line, type the

value, and press the ENTER key. This will place the value in the table

and move the cursor to the next available table entry. When you aresatisfied with the table entries, click on the STORE push button, thetable data will be stored, the dialog box will be closed and the property’scheck box on the Material Definition display will be highlighted in lightblue.

The GRAPH, ERASE, and CANCEL push buttons function in the sameway as described in the paragraphs above.

The syntax options for Material Properties will be presented below.

THERMAL PROPERTIESCONDUCTIVITY--may be specified as a constant, a linear function or a

quadratic function.Constant: Select the units from the following choices: {W/m/K |

cal/cm/C/sec | Btu/ft/F/sec | cal/cm/C/min | Btu/ft/F/min| cal/mm/C/sec | Btu/in/F/sec | Btu/in/F/min}

Enter the constant value to be used in the Edit Valueinput line.

Linear function: Select the Temperature from: {C | F | R | K} Select the Conductivity units from: {W/m/K | cal/cm/C/sec | Btu/ft/F/sec | cal/cm/C/min | Btu/ft/F/min| cal/mm/C/sec | Btu/in/F/sec | Btu/in/F/min}

Enter the temperatures in column one and Conductivityvalues in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Conductivity units from: {W/m/K | cal/cm/C/sec | Btu/ft/F/sec | cal/cm/C/min | Btu/ft/F/min| cal/mm/C/sec | Btu/in/F/sec | Btu/in/F/min}

Enter the temperatures in column one, the constantcoefficient in column two, the coefficient of temperaturein column three, and the coefficient of temperaturesquared in column four.

DENSITY--may be specified as a constant, a linear function or aquadratic function.

Constant: Select the units from the following choices: {kg/m**3

MATERIALS


| g/cc | g/mm**3 | lb/ft**3 | lb/in**3}


Linear function: Select the Temperature from: {C | F | R | K} Select the Density units from: {kg/m**3 | g/cc |g/mm**3 | lb/ft**3 | lb/in**3}

Enter the temperatures in column one and Densityvalues in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Density units from: {k/m**3 | g/cc | g/mm**3| lb/ft**3 | lb/in**3}


MATERIALS


SPECIFIC HEAT--may be specified as a constant, a linear function or aquadratic function.Constant: Select the units from the following choices: {kJ/kg/K |

cal/g/C | Btu/lb/F}


Linear function: Select the Temperature from: {C | F | R | K} Select the Specific Heat units from: {kJ/kg/K | cal/g/C |Btu/lb/F}

Enter the temperatures in column one and SpecificHeat values in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Specific Heat units from: {kJ/kg/K | cal/g/C |Btu/lb/F}


ENTHALPY--may be specified as a linear function or a quadraticfunction.Linear function: Select the Temperature from: {C | F | R | K}

Select the Enthalpy units from: {kJ/kg | cal/g | Btu/lb}

Enter the temperatures in column one and Enthalpyvalues in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Enthalpy units from: {kJ/kg | cal/g | Btu/lb}


MATERIALS


FRACTION SOLID--may be specified as a linear function or a quadraticfunction.Linear function: Select the Temperature from: {C | F | R | K}

Enter the temperatures in column one and FractionSolid values in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Enter the temperatures in column one, the constantcoefficient in column two, the coefficient of temperaturein column three, and the coefficient of temperaturesquared in column four.

CALC SOLID PATH--this push button results in the immediate action toopen a sub-menu which allows you to choose either SCHEIL orLEVER. As shown here, this sub-menu consists of two push buttons.

Note: The CALC SOLID PATHcapability will not be implementeduntil a release of ProCAST subsequent to 3.1.0.

SOLIDUS--is specified as a constant.Constant: Select the Temperature from: {C | F | R | K}


LIQUIDUS--is specified as a constant.Constant: Select the Temperature from: {C | F | R | K}


LATENT HEAT--is specified as a constant.Constant: Select the units from: {kJ/kg | cal/g | Btu/lb}


MATERIALS


FLUID PROPERTIESVISCOSITY may be specified as Newtonian or Non-Newtonian. When

you selecttheVISCOSITY propertycheck box,an optionmenu willbe displayed. As shown in this figure, the option menu consistsof two push buttons.

NEWTONIAN--Select Newtonian by clicking the NEWTONIANpush button. This will display an option menu fromwhich you may elect to describe the material’s viscosityas a constant, linear function or quadratic function.Constant: Select the units from the following choices:

{Pa.s | N.s/m**2 | centipoise | poise | lb/s/ft |lb/min/ft | lb/hr/ft}

Enter the constant value to be used in the EditValue input line.

Linear function: Select the Temperature from: {C | F |R | K} Select the Viscosity units from: {Pa.s |N.s/m**2 | centipoise | poise | lb/s/ft | lb/min/ft |lb/hr/ft}

Enter the temperatures in column one andViscosity values in column two.

Quadratic function: Select the Temperature from: {C |F | R | K} Select the Viscosity units from: {Pa.s |N.s/m**2 | centipoise | poise | lb/s/ft | lb/min/ft |lb/hr/ft}

Enter the temperatures in column one, theconstant coefficient in column two, thecoefficient of temperature in column three, andthe coefficient of temperature squared incolumn four.

MATERIALS


CARREAU-YASUDA--Select Carreau-Yasuda by clicking on it. This will display a menu which will allow you to describethe viscosity. This menu is shown here. You select themethod by clicking the desired method’s push button. Non-Newtonian values may be described as constantsor as linear functions. This method is described inEquation C.7.2 in Appendix C.

ZERO VISCOSITYConstant: Select the units from the following

choices: {Pa.s | N.s/m**2 | centipoise |poise | lb/s/ft | lb/min/ft | lb/hr/ft}

Enter the constant value to be used inthe Edit Value input line.

Linear function: Select the Temperature from: {C | F | R | K} Select the Viscosity units from: {Pa.s |N.s/m**2 | centipoise | poise | lb/s/ft |lb/min/ft | lb/hr/ft}

Enter the temperatures in column oneand Viscosity values in column two.

INFINITE VISCOSITYConstant: Select the units from the following





MATERIALS


PHASE SHIFTConstant: The units are sec/min


Linear function: Select the Temperature from: {C | F | R | K} The Viscosity units are sec/min


POWERConstant: Enter the constant value to be used

in the Edit Value input line.Linear function: Select the Temperature from:

{C | F | R | K}


YASUDAConstant: Enter the constant value to be used


{C | F | R | K}


MATERIALS


POWER-CUTOFF--Select Power-Cutoff by clicking on it. Thiswill display a menu which will allow you to describe theviscosity. This menu is shown here. You select themethod by clicking the on the desired method’s pushbutton. Power-Cutoff values may be described asconstants or as linear functions.

ZERO VISCOSITYConstant: Select the units from the following





K FACTORConstant: Select the units from the following

choices: {sec | min}


Linear function: Select the Temperature from: {C | F | R | K} Select the Phase Shift units from: {sec| min}

Enter the temperatures in column oneand Phase Shift values in column two.

MATERIALS


POWERConstant: Enter the constant value to be used


{C | F | R | K}

Enter the temperatures in column oneand Power values in column two.

SURFACE TENSION--may be specified as a constant, a linear functionor a quadratic function.Constant: Select the units from the following choices: {N/m |

dyne/cm | lb/ft | lb/in}


Linear function: Select the Temperature from: {C | F | R | K} Select the Surface Tension units from: {N/m | dyne/cm| lb/ft | lb/in}

Enter the temperatures in column one and SurfaceTension values in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Surface Tension units from: {N/m | dyne/cm| lb/ft | lb/in}


MATERIALS


PERMEABILITY--may be specified as a constant, a linear function or aquadratic function. If you provide this data, it will override permeabilitydata developed internally by ProCAST.

Constant: Select the units from the following choices: {m**2 |cm**2 | mm**2 | ft**2 | in**2}


Linear function: Select the Temperature from: {C | F | R | K} Select the Permeability units from: {m**2 | cm**2 |mm**2 | ft**2 | in**2}

Enter the temperatures in column one and Permeabilityvalues in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Permeability units from: {m**2 | cm**2 |mm**2 | ft**2 | in**2}


FILTER PROPERTIESVOID FRACTION--is specified as a constant.

Constant: Enter the constant value to be used in the Edit Valueinput line.

SURFACE AREA--is specified as a constant. This specifies the surfacearea to volume ratio.Constant: Select the units from: {1/m | 1/cm | 1/mm | 1/ft | 1/in}


MATERIALS


ELECTROMAGNETIC PROPERTIESPERMEABILITY--refers to magnetic permeability and may be specified

as a constant, a linear function or a quadratic function. Constant: Select the units from the following choices: {henry/m

| henry/cm | henry/mm | henry/ft | henry/in}


Linear function: Select the Temperature from: {C | F | R | K} Select the Permeability units from: {henry/m |henry/cm | henry/mm | henry/ft | henry/in}

Enter the temperatures in column one and Permeabilityvalues in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Permeability units from: {henry/m |henry/cm | henry/mm | henry/ft | henry/in}


MATERIALS


CONDUCTIVITY–refers to electrical conductivity and may be specifiedas a constant, a linear function or a quadratic function.

Constant: Select the units from the following choices: {ohm-m |ohm-cm | ohm-mm | ohm-ft | ohm-in}


Linear function: Select the Temperature from: {C | F | R | K} Select the Conductivity units from: {ohm-m | ohm-cm |ohm-mm | ohm-ft | ohm-in}

Enter the temperatures in column one and Conductivityvalues in column two.

Quadratic function: Select the Temperature from: {C | F | R |K} Select the Conductivity units from: {ohm-m | ohm-cm |ohm-mm | ohm-ft | ohm-in}


COMMENTS: This portion of the Material Description is a free formattext box which may be used to annotate the material. Forexample, you may want to describe the sources for anyproperty data or techniques used to develop the material or itsproperties.

Remarks The minimum requirements for the specific properties of a materialwhich must be provided depend upon the type of analysis you are goingto perform. The minimums for six general types of analysis areoutlined here. 1. Thermal analysis--Conductivity, Density, and Specific Heat. 2. Fluid (only)--Density and Viscosity. 3. Fluid-Thermal flow analysis--Conductivity, Density, Specific Heat,

and Viscosity. 4. Thermal and fluids coupled, with phase change--Conductivity,

Density, Liquidus, Solidus, Specific Heat, and Viscosity. 5. Stress--Conductivity, Density, Liquidus, Solidus, Young’s Modulus,

Thermal Expansion Coefficient, Poisson’s Ration, Density, andSpecific Heat.

6. Induction heating--Magnetic Permeability and ElectricalConductivity.

For a material undergoing phase change, there are three ways to

MATERIALS


account for the latent heat of fusion. 1. Modified specific heat function. This involves converting the latent

heat into an equivalent specific heat spike over the freezingrange.

2. A continuous enthalpy function can be generated by integrating thespecific heat over temperature along with the latent heat. Ifsuch a function is specified, it will take precedence over thespecific heat.

3. A user specified latent heat value many be used along with afraction solid curve and the specific heat, and ProCAST willautomatically compute an enthalpy curve.

The values of the liquidus and solidus temperature are used in a fluidsanalysis to determine when the material is in the mushy freezing range. A transition is made then to a D’Arcy type flow solution, i.e., porousmedia flow, rather than a full Navier-Stokes flow. If you are performinga thermal only solution, the liquidus and solidus temperatures have noeffect.

If you describe a property by entering data as a linear function oftemperature table and save the table, the linear function will overrideany value, for this property, which was specified in the constant window. If you describe a property by entering data as a piecewise quadraticfunction of temperature table and save the table, the quadratic functionwill override any value, for this property, which was specified in theconstant window or as a linear function.

The form of the quadratic function is F = A + BT + CT2. Thetemperature value for each row indicates the beginning of the range ofapplicability. There must be at least two rows filled out for the functionto be graphed. The temperature from the last row is used as the upperbound for the function. The A, B, and C values of the last row areignored and can be left blank. When a piecewise quadratic propertyfunction with multiple intervals is used in ProCAST, the function issearched from the highest temperature downwards to find the correcttemperature interval.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE

MATERIALS


Operateas Rotary

ToggleSwitches

Toggle Switches

Time Step UpdateFrequency

MATERIALSASSIGN

Description ASSIGN is a push button in the MATERIALS menu. It provides thecapability to associate properties from the database with element ID’s inthe model.

Method ASSIGN is activated by clicking on it. This results in the immediateaction to display a table containing a list of the material regions whichhave been defined in the model. It also displays a table of thematerials in thematerials database. The figure shownhere illustrates adisplay for a modelwith two MaterialRegions and theMaterial Databaseentries.

The background ofeach Region ID#,shown in column oneof this table, isdisplayed in a different color. Whenyou select an entryfrom this table byclicking on the ID#,the elements in themodel with acorresponding IDnumber will be drawnin the work windowpane in the samecolor as its respectivetable entry. You mayalso click in thesecond columnwithout redrawing themesh.

MATERIALS


To assign a material to a region of the model:1. Select the region by clicking the left mouse button when the cursor is

over the desired table entry.2. Select a material from the database by moving the cursor down to

the window displaying the MATERIAL DATABASE entries. Ifthe material you want is not visible in the table at first, you mayscroll to the desired entry.

3. When you have located the desired material entry, click on it.4. ASSIGN the material to the region by clicking the ASSIGN push

button. This will place the material name in column two of theAssignment Table.

To associate materials with other regions, repeat steps one throughfour.

In addition to associating materials with elements, ASSIGN providesthe capability to further define how each material is to be used in thesimulation. These definitions are indicated in columns three, four, andfive and represent TYPE, MOLD, and UPDATE respectively.

TYPE may contain one of four possible values. The entry in column

three, titled T, of each row is a rotary toggle switch. Successive

clicks on the contents of this column will cycle through thepossible choices. Valid material types are: T Thermal, F Fluid,I Filter, and O Foam.

When you change this setting, PreCAST checks the databaseto make sure that you have defined the properties required tosatisfy the TYPE designation you have specified.

Select the type of material from the following choices: {T | F | I |O}.

MOLD may contain Yes or No to indicate that this material is part of the

mold. The entry in column four, titled M, of each row is a

toggle switch. Successive clicks on the contents of this columnwill switch between the Y and N values.

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UPDATE may contain a value to indicate the time step frequency forintegrating the finite element matrices. By default this is doneat every time step. However, if the material properties varyslowly with temperature, as they typically do with molds, youmay wish to recompute the matrices much less frequently. Thissaves a considerable amount of CPU time.

Select a row from the Assignment table by clicking the leftmouse button when the cursor is over the desired entry. Movethe cursor to the Edit Value text input line. Type the numericalvalue to indicate the desired time step frequency and pressENTER. This will place the entered value in column five, titled

U, of the selected row.

When you are satisfied with the assignments and their T, M and Usettings, click on the QUIT push button in the Material Assignment tableor click on a push button in the Main Function Banner. This will storethe assignments and close the display.

Remarks The letter shown in column two, before a material name, in the MaterialDatabase display indicates that the minimum required properties havebeen defined for this material to be used in specific types ofsimulations.

The letter F indicates that the material has the minimum

required properties for a fluids simulation.

The letter T signifies that the minimum requirements for a

thermal only analysis are satisfied.

An asterisk * shows that there is insufficient data for the

material to be used in any type of simulation, except afluid only simulation. If you are performing a fluid onlyanalysis and this column is marked with an asterisk,you should verify that the Density and Viscosity havebeen specified for the material.

In practice, all non-fluid regions of the model should be specified as themold. This is particularly true if the simulation is to encompass anumber of casting cycles such as in die casting or permanent moldcasting. The material IDs which constitute the mold should be indicated

with a Y.

MATERIALS


You may examine and/or modify the material properties for MaterialDatabase entries by clicking the READ/MODIFY push button in theMaterial Database display window. This will display the MaterialDescription Display as shown here.

Further use of this capability is explained in the MATERIALSDATABASE section of this manual.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, MATERIALSDATABASE

MATERIALS


MATERIALSSTRESS

Description STRESS is a push button in the MATERIALS menu. It provides thecapability, through a sub-menu, to access the Stress Model Databaseand to associate stress model characteristics from the database withelement ID’s in the model. Using ProCAST’s DATABASE FACILITYyou may create, delete, or modify a stress model or its properties in thedatabase. These stress models may then be used for simulation andanalysis.

Method STRESS is activated by clicking on it. This results in the immediateaction to display a sub-menu. Asshown here, you may then choose toaccess the stress model database orproceed to the assign function.

PreCAST allows you to Read, Add,Copy, and Delete materials from theMaterials Database. Thesecapabilities are described in the DATABASE FACILITY section of thismanual. You should also refer to the TABLE MAINTENANCE sectionof this manual which describes ProCAST’s graphical interface formaintaining tables.

This section will discuss the requirements for adding a stress model tothe database and how you specify individual properties and attributesfor that model. This section will also discuss how you associateelements in your model with the stress database entries using theassign function.

You select from thesub-menu by clickingon the desiredfunction. When youclick on the DATABASE pushbutton in the sub-menu, it results in theimmediate action todisplay a tablecontaining any stressmodels which may bein the database. Thefigure shown hereillustrates a display ofthe models in the

MATERIALS


Stress Database.

To add a stress mechanical model to the database, click on the ADDpush button in the Stress Database display. This will result in theimmediate action to open a blank Stress Description which is shownbelow. Note that PreCAST has entered the USER name and the DATEfor you.

The minimum requirement for adding a stress model to the database isto give it a name and define its properties. The individual propertiesrequired depends upon the type of material selected and the modelingand analysis to be done.

The syntax and options available for the Stress Definition are discussedbelow.MATERIAL NAME: Enter the name you want to give the new material. The material name must begin with an alphabetic character and mayinclude upper and lower case characters.

MATERIALS


MATERIAL TYPE: Select the type of material you are adding. ProCAST displays the MATERIAL TYPE as a rotary toggle button. Successive clicks on this push button will cycle through the availablechoices. The available choices are:

LINEAR ELASTICPLASTIC, LINEAR HARDENINGPLASTIC, POWER LAW HARDENINGVISCOPLASTIC 1, LINEAR HARDENINGVISCOPLASTIC 1, POWER LAW HARDENINGVISCOPLASTIC 2, LINEAR HARDENINGVISCOPLASTIC 2, POWER LAW HARDENING

PROPERTIES:Properties are displayed as a group of check boxes or push buttons. Tospecify a property, click on the desired property’s check box. Selectinga property in this manner will result inthe immediate action to display anadditional option menu which willallow you to describe the property aseither a CONSTANT or as a LINEAR function. This option menu isshown here.

Properties which are not applicable to a specific material type will beshaded dark red. This is illustrated in the figure above, the FLUIDITY,YIELD STRESS, HARDENING PARAM., and VISOPLASTIC FLOWPOTENTIAL properties are not applicable for the LINEAR ELASTICmaterial type. Additionally, ProCAST dynamically displays propertynames based upon the material type option you have selected.

If you select the CONSTANT option, an input box similar to the oneshown here will be displayed. It will contain a text input line and maycontain a rotarytoggle switch for theunits of measure. Successive clicks onthis push button willtoggle through theavailable options. To enter the desired value for this property orattribute move the cursor to the text input line and type the value. When you click on the APPLY push button, the data entered will bestored, the dialog box will be closed, and the property’s check box onthe Stress Definition display will be highlighted in light blue.


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Selecting the LINEAR option will result in the immediate action todisplay an input table. This table, like the dialog box for a constant,may contain rotary toggle switches for the units of measure. As shownin this example for Elastic Modulus, there are two toggle switches whichalso serve as the column sub-headings for the table.

Select the desiredunits of measure byclicking on thecolumn heading pushbuttons. Successiveclicks on these pushbuttons will togglethrough the availableoptions. To enter atable value, selectthe first or nextavailable table entry,move the cursor tothe text input line,type the value, and

press the ENTER key.

This will place thevalue in the table andmove the cursor tothe next availabletable entry. Whenyou are satisfied with the table entries, click on the STORE push button,the data in the table will be stored, the dialog box will be closed, and theproperty’s check box on the Stress Definition display will be highlightedin light blue.


The syntax options for Stress Properties will be presented below. Forconvenience of presentation, all of the properties will be described here. In practice, ProCAST will only display those properties which are validfor each material type.

MATERIALS


ELASTIC MODULUSConstant: Select the units from the following choices: {N/m**2 |

Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi |lb/ft**2}


Linear function: Select the Temperature from: {C | F | R | K} Select the Elastic Modulus units from: {N/m**2 | Pa |KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi | lb/ft**2}

Enter the temperatures in column one and ElasticModulus values in column two.

FLUIDITYConstant: Select the units from the following choices: {1/sec |

1/min}Linear function: Select the Temperature from: {C | F | R | K}

Select the Fluidity units from: {1/sec | 1/min}

Enter the temperatures in column one and Fluidityvalues in column two.

HARDENING EXPONENTConstant: Enter the constant value to be used in the Edit Value

input line.Linear function: Select the Temperature from: {C | F | R | K}

Enter the temperatures in column one and HardeningData values in column two.

HARDENING PARAMETERConstant: Select the units from the following choices: {N/m**2 |



Linear function: Select the Temperature from: {C | F | R | K} Select the Hardening Data units from: {N/m**2 | Pa |KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi | lb/ft**2}

Enter the temperatures in column one and HardeningData values in column two.

MATERIALS


POISSON’S RATIOConstant: Enter the constant value to be used in the Edit Value


Enter the temperatures in column one and Poisson’sRatio values in column two.

STRENGTH PARAMETERConstant: Select the units from the following choices: {N/m**2 |



Linear function: Select the Temperature from: {C | F | R | K} Select the Yield/Strength units from: {N/m**2 | Pa |KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi | lb/ft**2}

Enter the temperatures in column one and theYield/Strength values in column two.

THERMAL EXPANSIONConstant: Select the units from the following choices: {1/K |

1/C | 1/F | 1/R}


Linear function: Select the Temperature from: {C | F | R | K} Select the Thermal Coefficient units from: {1/K | 1/C |1/F | 1/R}

Enter the temperatures in column one and ThermalCoefficient values in column two.

VISCOPLASTIC FLOW POTENTIALConstant: Enter the constant value to be used in the Edit Value


Enter the temperatures in column one and ViscoPotential values in column two.

MATERIALS


YIELD STRESSConstant: Select the units from the following choices: {N/m**2 |



Linear function: Select the Temperature from: {C | F | R | K} Select the Yield/Strength units from: {N/m**2 | Pa |KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi | lb/ft**2}

Enter the temperatures in column one andYield/Strength values in column two.

COMMENTS: This portion of the Stress Description is a free format textbox which may be used to annotate the material. For example,you may want to describe the sources for any property data ortechniques used to develop the stress model or its properties.

MATERIALS


ASSIGN is a push button in the STRESS sub-menu. It provides thecapability to associate properties from the database with element ID’s inthe model.

ASSIGN is activated by clicking on it. This results in the immediateaction to display a table containing a list of the material regions whichhave been defined in the model. It also displays a table of thematerials in thematerials database. The figure shownhere illustrates adisplay for a modelwith two MaterialRegions and theMaterial Databaseentries.

The background ofeach Region ID#,shown in column oneof this table, isdisplayed in a different color. Whenyou select an entryfrom this table byclicking on the ID#,the elements in themodel with acorresponding IDnumber will be drawnin the work windowpane in the samecolor as its respectivetable entry.

MATERIALS


To assign a stress model to a region of the model:1. Select the region by clicking on the desired table entry.2. Select a stress model from the database by moving the cursor down

to the window displaying the MATERIAL DATABASE entries. Ifthe material you want is not visible in the table at first, you mayscroll to the desired entry.

3. When you have located the desired material entry, click on it.4. ASSIGN the material to the region by clicking the ASSIGN push

button. This will place the material name in column two of theAssignment Table.

To associate stress models with other regions, repeat steps onethrough four.

When you are satisfied with the assignments, click on the QUIT pushbutton in the Assignment table. This will store the assignments andclose the display. You may close this display without storing any valuesby clicking the CANCEL push button.

Remarks If no assignment is made for a material, it will be taken as perfectly rigidin the stress analysis.

The use of mechanical model data is discussed in the MathematicalFormulations section of this manual.

If you describe a property by entering data as a linear function oftemperature table and save the table, the linear function will overrideany value, for this property, which was specified in the constant window.

You may examineand/or modify theStress Modelproperties forMaterial Databaseentries by clicking theREAD/MODIFY pushbutton in the MaterialDatabase displaywindow. This willdisplay the MaterialDescription Displayas shown here.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, MATERIALSDATABASE

MATERIALS


MATERIALSMICRO

Description MICRO is a push button in the MATERIALS menu. It provides thecapability, through a sub-menu, to access the Micro Model Databaseand to associate micro model characteristics from the database withmaterial ID’s in the model. Using ProCAST’s DATABASE FACILITYyou may create, delete, or modify a micro model or its properties in thedatabase. These micro models may then be used for simulation andanalysis.

Method MICRO is activated by clicking on it. This results in the immediateaction to display a sub-menu. Asshown here, you may then choose toaccess the micro model database orproceed to the assign function.

ProCAST allows you to Read, Add,Copy, and Delete micro models fromthe database. These capabilities aredescribed in the DATABASE FACILITY section of this manual. Youshould also refer to the TABLE MAINTENANCE section of this manualwhich describes ProCAST’s graphical interface for maintaining tables.

This section will discuss the requirements for adding a micro model tothe database and how you specify individual properties and attributesfor that model. This section will also discuss how you associateelements in your model with the micro database entries using theassign function.

You select from the sub-menu by clicking on the desired function.

When you click onthe DATABASEpush button in thesub-menu, it resultsin the immediateaction to display atable containing anymicro models whichmay be in thedatabase. Thefigure shown hereillustrates this tabledisplay, in thiscase, there are nomodels in the Micro

MATERIALS


PropertyCheck Box

RotaryToggleSwitch

Input TextLine

Database.

To add a micro model to the database, click on the ADD push button inthe Micro Database display. This will result in the immediate action toopen a sub-menu, asshown here, whichlists the types ofmicro models whichmay be defined.

The characteristics,input parameters,and options which areavailable or requiredvary from one micromodel to another.

When you choosefrom this menu,ProCAST will displaythe appropriate inputform and options in a blank Micro Description which is shown below. For convenience of illustration, the example shown is the result ofselecting the EQUIAXED DENDRITE option from the sub-menu.

Note that PreCAST has entered the USER name and the DATE for you.

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PreCAST has also entered, as a default, the KEYWORD which is thesame as the file prefix you entered when you started PreCAST. Theminimum requirement for adding a micro model to the database is togive it a keyword name and enter values for input parameters.

All of the micro model descriptions have two input text lines incommon: KEYWORD and COMMENTS. Specific other propertieswhich may be required, depend upon the type of micro model selectedand the types of materials to which this model is to be applied.

The syntax for the common entries are described below. Followingthese descriptions, the individual options for each available micromodel are discussed.

KEYWORD: Enter the name you want to give the micro modeldatabase entry. The key word must begin with an alphabetic character.

COMMENTS: This portion of the Micro Description is a free format textbox which may be used to annotate the material. For example, youmay want to describe the sources for any property data or techniquesused to develop the micro model or its properties.

PROPERTIES: Properties are displayed as a group of check boxes,push buttons, text input lines, or a combination of these. This isillustrated in the figure shown above for the Equiaxed Dendrite model. To enter data in a text input line, place the cursor in the text box, type

the desired data, and press ENTER. In some cases, the text input line

will be accompanied by a rotary toggle switch. These toggle switchesallow you to choose the desired value, usually a unit of measure, from alist of options. As shown in the example above, there are optional unitsof measure for the GIBBS-THOMPSON COEFFICIENT. Successiveclicks on the toggle switch will cycle through the available options forunits.

To specify a property which is displayed in a check box, click on thedesired property’s check box. This will result in the immediate action todisplay an additional option menu ora input dialog box. Some propertiesmay be specified either as constantsor as a linear function. An option menu, similar to the one shown here,will allow you to describe the property as either a CONSTANT or as afunction of COOLING RATE, TEMPERATURE, or COMPOSITION.

ProCAST dynamically displays the appropriate property names, optionboxes, and input text lines based upon the type of micro model optionyou select.

MATERIALS


If you select the CONSTANT option, an input box similar to the oneshown here will be displayed. It will contain a text input line. When a property requiresthat you specify theunits for theproperty, a rotarytoggle switch will bedisplayed in theinput box. Successive clicks on this push button will toggle through theavailable options. To enter the desired value for this property orattribute move the cursor to the text input line and type the value. When you click on the APPLY push button, the data entered will bestored, the dialog box will be closed, and the property’s check box onthe Micro Definition display will be highlighted in light blue.

You may click on theCANCEL push buttonto close the dialogbox without savingthe data.

Selecting theCOOLING RATE,TEMPERATURE, orCOMPOSITIONoption will result inthe immediate actionto display an inputtable. This table, likethe dialog box for aconstant, maycontain rotary toggleswitches for the unitsof measure. Asshown in thisexample for Transformation Temperature, there are two toggle switcheswhich also serve as the column sub-headings for the table.

Select the desired units of measure by clicking on the column headingpush buttons. Successive clicks on these push buttons will togglethrough the available options.

To enter a table value, select the first or next available table entry,move the cursor to the text input line, type the value, and press theENTER key. This will place the value in the table and highlight the next

available table entry. When you are satisfied with the table entries,click on the SAVE push button, the data in the table will be stored, thedialog box will be closed, and the property’s check box on the Micro

MATERIALS


Definition display will be highlighted in light blue.


The syntax and options for Micro Model Properties will be presentedbelow. For convenience of presentation, the micro models arepresented in alphabetical order.

MATERIALS


CAFE MODEL

Editor’s Note: The CAFE capability has not yet been implemented in ProCAST.

AVERAGE UNDERCOOLING

Editor’s Note: discussion to be added.

Constant: Enter the constant value to be used in the input line.

GROWTH COEFFICIENT 1 and 2


Constant: Enter the constant value to be used in the input line.MAX NUCLEATION SITES



STD DEVIATION



MATERIALS


COUPLED EUTECTICThe Coupled Eutectic Growth Models are divided into two categories:Instantaneous Nucleation andContinuous Nucleation. Selecting the COUPLEDEUTECTIC model results inopening another sub-menuwhich provides you with the option to specify either instantaneous orcontinuous nucleation. This sub-menu is shown here. You select thedesired option by clicking the appropriate push button. These modelscan be applicable to both regular and irregular eutectics. These modelsalso address the growth of both the stable and metastable eutectic. Either selection will result in displaying the input form shown here. Theonly difference is that the SUBSTRATE DENSITY is given as a functionof temperature instead of cooling rate in the CONTINUOUSNUCLEATION model.

In the case ofcontinuousnucleation,nucleation begins atthe specified nucleationtemperature andcontinues until themaximumundercooling point inthe cooling curve isreached. Oncenucleated, the nucleikeep on growing. Beyond the point ofmaximumundercooling,nucleation ceasesand the growthprocess becomes more dominant and the cooling curve showsrecalescence.

For instantaneous nucleation, you specify the substrate density as afraction of cooling rate with the assumption that nucleation occurs at aunique temperature instantaneously.

MATERIALS


CRITICAL COOLING RATE is the rate at which you get the stable-to-metastable eutectic transition. For a given melt chemistry, thiscan be obtained from simple experiments.

You should enter the absolute value of the cooling rate. If youare using this model for stable eutectic growth only, then entera very high value for the critical cooling rate parameter. Thiswill avoid any formation of metastable eutectic.

Constant: Select the Cooling Rate units from the followingchoices: {K/sec | F/sec | C/sec | R/sec | K/min | F/min |C/min | R/min}

Enter the constant value to be used in the input line.

LAMELLAR SPACING is used for modeling the growth of metastableeutectic. These data must be obtained from experiment. Withincreasing cooling rate, the lamellar spacing is expected todecrease.

Linear function: Select the Cooling Rate units from: {K/sec |F/sec | C/sec | R/sec | K/min | F/min | C/min | R/min}Select the Lamellar spacing units from: {m | cm | mm |ft | in}

Enter the cooling rate values in column one andLamellar spacing values in column two.

METASTABLE GROWTH CONSTANTConstant: Select the units from: {m/sec/K**2 | cm/sec/K**2 |

mm/sec/K**2 | ft/sec/F**2 | in/sec/F**2 | m/min/K**2 |cm/min/K**2 | mm/min/K**2 | ft/min/F**2 | in/min/F**2}


PARTITION COEFFICIENT gives the ratio of solute content in the solidto that in the liquid. Often, this quantity is less than one,signifying that solute will be rejected into the liquid at thesolid/liquid interface. When this quantity is greater than one,the region just ahead of the solid/liquid front is depleted ofsolute (below the base level). This parameter has no unit. Thisinformation is needed to calculate the instantaneous stableeutectic temperature as solidification proceeds. Duringeutectic growth, the solute level will change in the liquid regionof a eutectic grain as solidification proceeds. Depending on theamount of solute in the liquid, the eutectic temperature willchange. However, the metastable eutectic temperature isassumed to be stationary at this point. The partition coefficient

MATERIALS


may be entered as a constant or as a function of temperature. The temperature function should be used when the liquidusslope in the binary phase diagram is not constant.Constant: Enter the Partition Coefficient value in the input line.

Linear function: Select the Temperature from: {C | F | R | K}

Enter the temperatures in column one and PartitionCoefficient values in column two.

SOLVENT MELTING POINT refers to the melting point of the solventelement or of the pure metal. For example, if your material is aFe-4.3%C eutectic, you will enter the melting point of pure Feas the solvent melting point. Here iron is the solvent andcarbon is the solute.

Constant: Select the Temperature from: {C | F | R | K}


STABLE GROWTH CONSTANT is the proportionality constantdescribing the growth rate of eutectic cells which is proportionalto the square of the undercooling ahead of the solid/liquidinterface. A typical value for a Fe-Graphite eutectic in cast ironis of the order of 7e-7 cm/sec/K2. This number will varydepending on the material chosen. For a given material, thisnumber may be obtained from the appropriate growthmechanism or from the literature.Constant: Select the units from: {m/sec/K**2 | cm/sec/K**2 |

mm/sec/K**2 | ft/sec/F**2 | in/sec/F**2 | m/min/K**2 |cm/min/K**2 | mm/min/K**2 | ft/min/F**2 | in/min/F**2}


MATERIALS


SUBSTRATE DENSITY is used to enter nucleation data. Substratedensity can be entered as a function of either the cooling rate ortemperature depending upon whether you chose theInstantaneous or the Continuous Nucleation model. Basedupon that choice, PreCAST will display the correct input dialogoptions when you select the SUBSTRATE DENSITYparameter. If you chose Instantaneous, you will specify thesubstrate density as a function of the cooling rate. If you choseContinuous, you will specify the substrate density as a functionof temperature.

Allowing the substrate density to vary as a function of coolingrate allows for a non-uniform distribution of grain sizes across acasting. If you expect to have metastable eutectic formation,one of the entries should contain the critical cooling rate withthe corresponding value of substrate density for the metastableeutectic.

You may need to obtain this data from a carefully conductedexperiment. As long as the melt chemistry and processparameters do not change very much, these data can be usedfor different simulations.

For Instantaneous, specify:Linear function: Select the Cooling Rate units from : {K/sec |

C/sec | F/sec | R/sec | K/min | C/min | F/min | R/min}

Select the Substrate Density units from: {1/m**3 |1/cm**3 | 1/mm**3 | 1/ft**3 | 1/in**3}

Enter the Cooling Rate values in column one andSubstrate Density values in column two.

For Continuous, specify:Linear function: Select the Temperature units from : {C | F | R |

K}


Enter the Temperature values in column one andSubstrate Density values in column two.

MATERIALS


TRANSFORMATION TEMPERATURE refers to the temperature atwhich eutectic solidification begins to nucleate in the liquid. This parameter can be a constant or a function of cooling rate. With an increase in cooling rate, the transformationtemperature is expected to drop from the equilibrium value. Inthe case of a stable to metastable transition, the critical coolingrate value you chose needs to be one of the entries in thetransformation temperature vs. cooling rate table.

Constant: Select the Temperature from: {K | F | C | R}Enter the Transformation Temperature in the EditValue line.

Linear function: Select the Cooling Rate units from : {K/sec |C/sec | F/sec | R/sec | K/min | C/min | F/min | R/min}

Select the Transformation Temperature units from: { K |F | C | R}

Enter the Cooling Rate values in column one andTransformation Temperature values in columntwo.

DUCTILE IRON EUTECTICThe eutectic growth process in ductile iron is a divorced growth of

austenite andgraphite, which donot growconcomitantly. Thisgrowth is simulatedbeginning with aninstantaneousnucleation modeland a growth modelthat solves thediffusion a carbonfrom liquid throughthe austenitic shellinto graphite nodule.

MATERIALS


TRANSFORMATION TEMPERATURE refers to the temperature atwhich eutectic solidification begins. This parameter can be aconstant or a function of cooling rate. With an increase incooling rate, the transformation temperature is expected to dropfrom the equilibrium value.




Enter the Cooling Rate values in column one andTransformation Temperature values in column two.

NODULE COUNT allows you to describe the nucleation data. Thenucleation law used is instantaneous in nature, meaning that allthe grains are nucleated at the same temperature. You maychoose to enter the nucleation data as a function of the coolingrate. Normally, a high value of nodule count is associated witha high value of cooling rate. However, if you wish to use aconstant value for the nodule count, you may enter twoidentical values of the nodule count for a desired range ofcooling rates. Be careful about the unit of nodule count. Thenumber required here should be per unit volume.


Select the Nodule Count units from: {1/m**3 | 1/cm**3 |1/mm**3 | 1/ft**3 | 1/in**3}

Enter the Cooling Rate values in column one andNodule Count values in column two.

MATERIALS


DUCTILE IRON EUTECTOIDThis model is used to simulate the solid state transformation in ductileiron. It may be used during the eutectoid transformation whiledescribing the complete phase transformation of ductile iron frompouring temperature to room temperature. It may also be used when

the iron is heatedfrom roomtemperature to theaustenitizingtemperature and thenannealed ornormalized as part ofa heat treatmentprocedure.

This model simulatesthe decomposition ofaustenite into ferriteand graphite at the

stable eutectoid temperature and austenite to pearlite at the metastableeutectoid temperature. These stable and metastable temperatures areknown from the literature. Usually this model should be used inconjunction with the eutectic ductile iron model. However, if you arejust interested in modeling the solid state transformation starting from atemperature less than the eutectic temperature, then you may use thismodel alone.

TRANSFORMATION TEMPERATURE is used to enter the eutectoidtransformation temperature as a constant or as a function ofcooling rate. The maximum stable eutectoid temperature usedis 1063 (K. Therefore, your transformation temperature shouldbe � 1063 (K and greater than the metastable eutectoidtemperature, which is taken as 1033 (K.

Constant: Select the Temperature from: {K | F | C | R}

Enter the Transformation Temperature in the EditValue line.




MATERIALS


NODULE COUNT allows you to describe the nucleation data. Thenucleation law used is instantaneous in nature, meaning that allthe grains are nucleated at the same temperature. You maychoose to enter the nucleation data as a function of the coolingrate. Normally, a high value of nodule count is associated witha high value of cooling rate. However, if you wish to use aconstant value for the nodule count, you may enter twoidentical values of the nodule count for a desired range ofcooling rates. Be careful about the unit of nodule count. Thenumber required here should be per unit volume. If you have aeutectic model for the liquid/solid transformation, then the samenodule count values may be entered here.


Select the Nodule Count units from: {1/m**3 | 1/cm**3 |1/mm**3 | 1/ft**3 | 1/in**3}

Enter the Cooling Rate values in column one andNodule Count values in column two.

EQUIAXED DENDRITEThis model is based on instantaneous nucleation, whereby the finalgrain size is known from the nucleation model.

MATERIALS


ALLOY COMPOSITION refers to the composition of the solute insolvent in wt% units. For example, if your casting material is a binaryAl-7%Si alloy, then you would set the alloy composition to 7 (wt%). Fora multi component alloy system, one needs to use an approximatepseudo-binary system and enter the weighted solute content. Forexample, in case of cast iron the appropriate procedure will be to enterthe carbon equivalent value.


DIFFUSIVITY is used to describe the solute diffusivity in liquid. Thisparameter may be a constant quantity or a function oftemperature. Generally, diffusivity is expected to change withtemperature as solidification proceeds.

Constant: Select the Diffusivity units from the following choices: {m**2/sec | cm**2/sec | mm**2/sec | ft**2/sec | in**2/sec| m**2/min | cm**2/min | mm**2/min | ft**2/min |in**2/min}


Linear function: Select the Temperature units from: {K | C | F |R}Select the units from: {m**2/sec | cm**2/sec |mm**2/sec | ft**2/sec | in**2/sec | m**2/min | cm**2/min| mm**2/min | ft**2/min | in**2/min}

Enter the temperatures in column one and DiffusivityData values in column two.

GIBBS-THOMPSON coefficient is used for calculating the curvatureundercooling at the dendrite tip. A typical value for an Al-Sialloy is 2.0 * 10-7 m*K. This is a material constant.

Constant: Select the units from: {m*K | cm*K | mm*K | ft*F |in*F}


MATERIALS


LIQUIDUS SLOPE corresponds to the liquidus slope in a binary or apseudo-binary phase diagram. Please note that the slope isexpected to be a negative quantity and you may have to selectthe appropriate side of the phase diagram. The liquidus slopecan be a constant quantity or a linear function of solutecomposition. If you select the function of composition, makesure that you enter solute concentration in wt %.Constant: Select the Liquidus Slope units from the following

choices: {K/wt% | C/wt% | F/wt% | R/wt%}


Linear function: Select the Liquidus Slope units from: {K/wt% |C/wt% | F/wt% | R/wt%}

Enter the Solute Concentrations in column one andLiquidus Slope data values in column two.

PARTITION COEFFICIENT gives the ratio of solute solubility in thesolid to the liquid. Often, this quantity is less than one,signifying that solute will be rejected ahead of the dendrite tip. When this quantity is greater than one, the region just ahead ofthe tip is depleted of solute (below the base level). Thisparameter has no unit. This parameter may be given as aconstant or as a function of temperature. The temperaturefunction should be used when the liquidus slope in the binaryphase diagram is not constant.Constant: Enter the Partition Coefficient value in the input line.


Enter the temperatures in column one and PartitionCoefficient Data values in column two.

MATERIALS


SUBSTRATE DENSITY is used to enter nucleation data. Thenucleation law used is instantaneous. However, substratedensity is allowed to vary as a function of cooling rate. Thisallows for a non-uniform distribution of grain sizes across acasting.

You may need to obtain this data from a carefully conductedexperiment. As long as the melt chemistry and processparameters do not change very much, these data can be usedfor different simulations. A continuous nucleation law cannotbe used with this model.



Enter the Cooling Rate values in column one andSubstrate Density values in column two.

TRANSFORMATION TEMPERATURE refers to the temperature atwhich the equiaxed dendrites begin to nucleate in the liquid. This parameter can be a constant or a function of cooling rate. With an increase in cooling rate, the transformationtemperature is expected to drop from the equilibrium value.





MATERIALS


GRAY IRON EUTECTOIDThe gray iron eutectoid transformation model is used to simulate the

solid statetransformation ingray iron. Nucleationand growth of ferritetakes place once thetemperature dropsbelow the stableeutectoidtransformationtemperature. If thetransformation ofaustenite is notcomplete when themetastable eutectoid

temperature is reached, then nucleation and growth of pearlite takesplace.

This model simulates the decomposition of austenite into ferrite andgraphite at the stable eutectoid temperature and to pearlite at themetastable eutectoid temperature. This model uses a statistical modelfor the nucleation law. Also, it uses the values of growth constants ofdifferent phases from the literature.

TRANSFORMATION TEMPERATURE refers to the temperature atwhich eutectic solidification begins or the equiaxed dendritesbegin to nucleate in the liquid. This parameter can be aconstant or a function of cooling rate. With an increase incooling rate, the transformation temperature is expected to dropfrom the equilibrium value.





MATERIALS


GRAY/WHITE IRON EUTECTICThis model is a special case of coupled eutectic growth model and isapplicable to cast iron only. In cast iron, one may obtain both gray and

white iron dependingon the meltcomposition andcooling conditions. Given a controlledmelt composition, themost important factorthat will determinewhether a givenregion will solidify aswhite or gray is thecooling rate.

This model differsfrom the Coupled

Eutectic Growth Models in that the nucleation is described by astatistical nucleation law.

The growth constant values for gray and white iron are obtained fromthe literature. The COUPLED EUTECTIC GROWTH MODEL can alsobe used for modeling the solidification of eutectic gray/white iron.

GRAY TO WHITE TRANSITION COOLING RATE--you are required toenter the critical cooling rate for the gray to white transition. This parameter should be determined from experiment.

Constant: Select the units from the following choices: {K/sec |C/sec | F/sec | R/sec | K/min | C/min | F/min | R/min}


MATERIALS


TRANSFORMATION TEMPERATURE refers to the temperature atwhich eutectic solidification begins. This parameter can be aconstant or a function of cooling rate. With an increase incooling rate, the transformation temperature is expected to dropfrom the equilibrium value. Special care are must be taken inthe case of a stable to metastable transition. The criticalcooling rate value you chose needs to be one of the entries inthe transformation temperature vs. cooling rate table. Thecritical cooling rate value should correspond to the appropriatemetastable eutectic temperature. The metastable eutectictemperature is a constant quantity.





MATERIALS


PERITECTIC TRANSFORMATIONIn a peritectic transformation, liquid reacts with an existing solid phaseto form a new solid phase. Once the new solid phase is formed, furtherreaction between the parent phases is limited by the layer of solidformed. Therefore the rate of reaction is controlled by the diffusion ofsolute through this layer of the transformed product.

ALLOY COMPOSITION refers to the composition of the solute insolvent in wt% units. For a multi component alloy system, oneneeds to use an approximate pseudo-binary system and enterthe weighted solute content.


EUTECTIC COMPOSITION refers to the final composition that theliquid reaches before the end of solidification. Normally,solidification finishes with a terminal eutectic reaction. Forexample, you would enter 4.3% as the eutectic compositionwhen the material you selected is cast iron.


MATERIALS


GIBBS-THOMPSON coefficient is used for calculating the curvatureundercooling at the dendrite tip. A typical value for an Al-Sialloy is 2.0 * 10-7 mK.

Constant: Select the units from: {m*K | cm*K | mm*K | ft*F |in*F} Enter the constant value to be used in the input line.

LIQUID DIFFUSIVITY refers to the diffusion coefficient of the soluteelement in the liquid phase. In the Fe-C system, this is thediffusion coefficient of carbon or carbon equivalent in liquid.





MATERIALS


LIQUIDUS SLOPE corresponds to the liquidus line in a binary or apseudo-binary phase diagram. Please note that the slope isexpected to be a negative quantity. The liquidus slope can bea constant quantity or a linear function of solute composition. Ifyou select the function of composition, make sure that youenter solute concentration in wt %.

The figure shown here is a schematic representation of the Fe-C peritectic region. The liquidus slope refers to the slope of theline AD. The letter P refers to the peritectic point. In thisfigure, the equilibrium amount of Reacting Fraction of Solid isgiven as the ration of PD over ED.

Constant: Select the Liquidus Slope units from the followingchoices: {K/wt% | C/wt% | F/wt% | R/wt%}




MATERIALS


REACTING FRACTION OF SOLID refers to the amount of solidfraction reacting with the liquid phase to produce the new solidphase. In the peritectic reaction, it means the amount of theprimary phase that is reacting with liquid. Actually, this numbershould be obtained with an equiaxed dendrite model for thegrowth of the delta phase. However, for the time being, you willhave to enter here the equilibrium amount of the primaryphase.


SOLID FORMING PARTITION COEFFICIENT refers to the partitioncoefficient of the solute element in the phase being formed andthe liquid phase. In the context of the Fe-C system, thisparameter refers to the partition coefficient of carbon or carbonequivalent among the gamma and the liquid phase. Thiscoefficient can be constant or functions of temperature.




SOLID REACTING DIFFUSIVITY is the diffusion coefficient of thesolute element in the reacting solid phase. In the Fe-C system,this is the diffusion coefficient of carbon in the delta phase. This diffusivity parameter may be a constant or a function oftemperature.





MATERIALS


SOLID REACTING PARTITION COEFFICIENT refers to the partitioncoefficient of the solute element among the reacting solidphase and the liquid phase. For the Fe-C system, this meansthe partition coefficient of carbon or carbon equivalent amongthe delta and the liquid phase. This coefficient can be constantor functions of temperature.




SOLID FORMING DIFFUSIVITY refers to the diffusion coefficient of thesolute element in the forming solid phase. In the Fe-C system,this is the diffusion coefficient of carbon in the gamma phase. The diffusivity parameter may be a constant or a function oftemperature.





MATERIALS


TRANSFORMATION TEMPERATURE refers to the temperature atwhich peritectic reaction starts. This can be a constant quantityor a function of temperature.





SCHEILThe Scheil model makes the assumptions of complete mixing of solutein liquid and no solute diffusion in the solid phase.

ALLOY COMPOSITION refers to the composition of the solute insolvent in wt% units. For a multi component alloy system, oneneeds to use an approximate pseudo-binary system and enterthe weighted solute content.


MATERIALS


FINAL TEMPERATURE usually corresponds to the eutectictemperature or the temperature at which the solidification ends. If the eutectic temperature value is entered here, then evolutionof fraction of solid by this model will stop and an eutecticgrowth model, if chosen, will control the remaining solidificationprocess.

Constant: Select the Temperature from: {C | F | R | K} Enter the constant value to be used in the input line.

LIQUIDUS SLOPE corresponds to the liquidus line in a binary or apseudo-binary phase diagram. Please note that the slope isexpected to be a negative quantity. The liquidus slope can bea constant quantity or a linear function of solute composition. Ifyou select the function of composition, make sure that youenter solute concentration in wt %.

Constant: Select the Liquidus Slope units from the followingchoices: {K/wt% | C/wt% | F/wt% | R/wt%}




PARTITION COEFFICIENT gives the ratio of solute solubility in thesolid to the liquid. Often, this quantity is less than one,signifying that solute will be rejected ahead of the dendrite tip.

Constant: Enter the Partition Coefficient value in the input line.Linear function: Select the Temperature from: {C | F | R | K}

Enter the temperatures in column one and PartitionCoefficient Data values in column two.

MATERIALS


SOLVENT MELTING POINT refers to the melting point of the solventelement or of the pure metal. For example, if your material is aFe-4.3%C eutectic, you will enter the melting point of pure Fe. Here iron is the solvent and carbon is the solute.

Constant: Select the units from the following choices: {K | F | C| R}


TRANSFORMATION TEMPERATURE refers to the temperature atwhich the solidification begins. This parameter can be aconstant or a function of cooling rate.





SOLID TRANSFORMATIONSThis model is only applicable to the Fe-C system and is used fortracking the fractiontransformed for thecases of delta togamma, gamma toferrite, and gamma tocementite. If the wt%of carbon equivalentis less than or equalto 0.17%, the delta togammatransformation will beactivated in theappropriatetemperature range. The value of this carbon equivalent will control whether gamma toferrite or gamma to cementite will take place during subsequent theproeutectoid transformation.

WT% CARBON EQUIV

MATERIALS



ASSIGN is a pushbutton in the MICROsub-menu. It providesthe capability toassociate propertiesfrom the databasewith material ID’s inthe model.

ASSIGN is activatedby clicking on it. Thisresults in theimmediate action todisplay a tablecontaining a list of thematerial regionswhich have beendefined in the model. It also displays a tableof the material micromodels in thedatabase. The figureshown here illustratesa display for a modelwith two MaterialRegions and theMicro Databaseentries.

When you select an entry from this table by clicking on the ID# or theMaterial Name, the elements in the model with a corresponding IDnumber will be redrawn in the work window pane in a color unique tothe respective table entry.

MATERIALS


To assign a micro model to a region of the model:1. Select the region by clicking the desired table entry.2. Select a material from the database by moving the cursor down to

the window displaying the MICRO DATABASE entries. If themodel you want is not visible in the table at first, you may scrollto the desired entry.

3. When you have located the desired micro model entry, click on it.4. ASSIGN the material to the region by clicking the ASSIGN push

button. This will place the database entry number in columnthree of the Assignment Table.

To associate micro models with other regions, repeat steps one throughfour.

You may examine and/or modify the properties for Micro Databaseentries by clicking the READ/MODIFY push button in the MicroDatabase display window.

When you are satisfied with the assignments, click on the QUIT pushbutton in the Assignment Table. This will store the assignments andclose the display. You may close this display without storing anyassignments by clicking the CANCEL push button.

Remarks The ultimate aim of micromodeling is to predict the microstructure ofcastings. The mechanical properties of the castings can then bepredicted from a knowledge of the microstructure.

Micromodels can not accomplish this task alone however. They haveto be incorporated into macromodels to achieve this goal. Coupling themacro- and micromodels is accomplished through the source term inthe energy equation. The rate of evolution of the fraction of solid iscalculated by the micromodels, which controls the release of latentheat.

A combination of different micromodels can be chosen in a singlesimulation run by adding the appropriate MICRO parameterscorresponding to individual micromodels. This is done automatically inPreCAST when different micromodels are assigned to the differentmaterials in the model. PreCAST allows you to assign the desiredmicromodels to the particular material.

The rest of this section will discuss specific issues related to individualmicro models. For convenience of presentation, these will bepresented alphabetically.

MATERIALS


COUPLED EUTECTIC--should be selected when the material chosenwill solidify at some stage in a eutectic mode. The eutecticcould be a stable or metastable. Both the regular and theirregular eutectic solidification are described with this model. The growth of either stable or metastable eutectic may proceedfollowing either an instantaneous or continuous nucleation law. In the case of regular eutectics, growth of both phases of theeutectic structure are non-faceted in nature. For irregulareutectic, the growth process of one of the phases is faceted. Growth of the faceting phase requires considerably higherentropy of fusion. Examples of faceted growth are graphitegrowth in stable austenite/graphite eutectic and Silicon in Al-Sieutectic. The metastable austenite/ cementite eutectic is anexample of non-faceted/non-faceted type eutectic growth.

Growth of both the stable and metastable eutectic areaddressed here. Growth of the stable eutectic usually proceedsat a higher temperature. For example, the difference betweenthe stable and metastable eutectic temperature in cast iron isabout 6 (C. This value may, however, be influenced by theamount of alloying elements present. A higher cooling rateresults in the formation of a metastable eutectic.

All of the nucleation and growth types of micromodelsdiscussed here assume bulk heterogeneous nucleation atforeign sites which are already present within the melt orintentionally added to the melt by inoculation. So these modelsare valid for the equiaxed region of castings.

The instantaneous nucleation model is modified to take intoaccount the dependance of cooling rate on the number ofnucleation sites or substrates. With an increase in cooling rateor undercooling, the number of substrates increases whichexplains the existence of more grains in faster cooled regionsof a casting.

In continuous nucleation, the process starts at the nucleationtemperature and proceeds until the stage when the minimum inthe cooling curve is attained.

Regardless of the nucleation process, the models assume thatthe grains are equiaxed and that they grow freely in liquid asspheres until they impinge on each other. The micromodelsuse a correction factor for impingement of grains. The growthprocess stops when all the liquid is consumed.

MATERIALS


DUCTILE IRON EUTECTIC--At the beginning of the liquid/solidtransformation, graphite nodules nucleate in the liquid and growin the liquid to a small extent. The formation of graphitenodules and their limited growth in liquid depletes the meltlocally of carbon in the vicinity of the nodules. This facilitatesthe nucleation of austenite around the nodules, forming a shell. Further growth of these nodules is possible by diffusion ofcarbon from the melt through the austenite shell to the graphitenodule.

ProCAST simulates this growth beginning with aninstantaneous nucleation model that determines the final grainsize from the local cooling rate at the onset of solidification. Once the austenite shell is formed around each nodule, thediffusion equation for carbon through the austenitic shell issolved. Boundary conditions are known from the phasediagram because thermodynamic equilibrium is maintainedlocally. Conservation of mass and solute is maintained in eachgrain. Because of the density variation resulting from thegrowth of austenite and graphite, the expansion/contraction ofthe grain is taken into account by allowing the final grain size tovary. Toward the end of solidification, the grains impinge oneach other.

DUCTILE IRON EUTECTOID--The eutectoid reaction leads to thedecomposition of austenite into ferrite and graphite for the caseof the stable eutectoid and to pearlite for the metastableeutectoid transformation. Usually, the metastable eutectoidtemperature is lower than the stable eutectoid temperature. Slower cooling rates result in more stable eutectoid structure.

EQUIAXED DENDRITE--This model should be used to simulate theprimary phase solidification of an off-eutectic alloy.

GRAY IRON EUTECTOID--The gray iron eutectoid transformationmodel is based on the approach used for gray iron eutectic anda statistical distribution is assumed. In this statistical approach,nucleation and growth takes place once the temperature dropsbelow the transformation temperature. When nucleation endsat the minimum point of the cooling curve, the existing nucleicontinue growing until the transformed fraction becomes 1. The number of nuclei does not change from this point on.

MATERIALS


GRAY/WHITE IRON EUTECTIC--This model is a special case ofcoupled eutectic growth model and is applicable to cast irononly. If a region of a casting solidifies with a cooling rate higherthan the critical cooling rate, then it will be white. The reverseis the case for gray iron. The white structure is brittle and inmost gray iron castings, it is considered to be deleterious. Thismodel describes nucleation by a continuous distributionfunction.

PERITECTIC TRANSFORMATION--In conventional models, a newsolid is assumed to form at the interface between the parentliquid and solid phases in a peritectic transformation when theliquid reacts with an existing solid phase. Once the new solidphase is formed, the rate of reaction is controlled by thediffusion of solute through the shell of the transformed product. Some researchers have suggested that the peritectictransformation may be achieved through a liquid layer betweenthe parent and the product solid phases. This mechanism hasbeen adopted in the present model.

More detailed discussion about these properties, models, data, andtheir use may be found in the Mathematical Formulations Appendix.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, MATERIALSDATABASE, MATHEMATICAL FORMULATIONS

MATERIALS


MATERIALSINVERSE

Description INVERSE is a push button in the MATERIALS menu which allows youto select the materials in the model for which the thermophysicalproperties will be calculated using the inverse calculation method. These calculations will be based upon the geometry, initial conditions,boundary conditions, and thermal history.

Method INVERSE is activated byclicking on it. This results inthe immediate action todisplay a table displaying alist of the materials in themodel. The figure shownhere illustrates this display.

As shown in this figure, thereare three columns on theright side of the table. Theheadings are: Cp–Specificheat per unit mass, K--Thermal conductivity, and L--Latent heat. Beneath these headings are rows of toggle switches. There is one rowof switches for each material in the table. You specify the materialproperties for each material which are to be calculated using theinverse calculation method by toggling the corresponding switch to theY or yes position.

Successive clicks on these switches will toggle between Y and N or no.

Remarks If you do Materials--Inverse, you cannot concurrently do either theinterface or boundary condition determinations using the inversemethod.

Related Topics MATERIALS

INTERFACE


INTERFACE

Description INTERFACE is a push button in the Main Function Banner. Thisfunction of PreCAST enables you to describe the thermal interfacesbetween dissimilar material IDs. It also enables you to add, modify anddelete interfacial heat transfer coefficient information in the databaseand assign these specific interface descriptions to elements in themodel. When you activate the INTERFACE push button, a menu isopened which will allow you to choose the interface operation you wishto perform. Selections from the menu provide capabilities which will bediscussed in this section.

Method INTERFACE is activated by clicking on it. The initial menu is shownhere. When you select a function fromthis menu, PreCAST will displayadditional Dialog Boxes, Option Lists,Data Input Windows, or sub-menus. These graphical interface tools will guideyou through the process of specifying,changing or deleting information aboutthe interfaces in the database.

You may leave the INTERFACE function by clicking another pushbutton in the Main Function Banner.

Remarks ProCAST provides the capability and flexibility to add, delete, or modifyan interface in the interface database. Once Interface data is in thedatabase, you can proceed to the ASSIGN function to associate theseinterface definitions with specific elements in the model.

The major capabilities of the INTERFACE function of PreCAST will besummarized here. Each capability will be described in greater detail inthis manual.DATABASE

Provides the data management functions for the interfacedescriptions and their respective properties in your database.DATABASE allows you to add, delete, copy, and modify entriesin the interface database.

CREATEProvides the capability to create coincident nodes betweenpairs of adjacent materials.

INTERFACE


ASSIGNProvides the capability to associate interface properties withelements in the model.

MULTI-POINTSProvides the capability for you to “glue” together elementregions when the nodes do not align. Multi-points can only beused in a thermal solution or in the mold of a fluids analysis.

INVERSEProvides the capability to configure the problem to use theinverse calculation method for the determination of interfaceheat transfer coefficients.

ProCAST’s graphical user interface provides a straight forward andsimple procedure for working with the various databases used byProCAST. This database facility is described elsewhere in this manual. You should read about this facility before attempting to modify theinterface database.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, INTERFACE--DATABASE, INTERFACE--CREATE, DATABASE--ASSIGN,DATABASE--MULTI-POINTS, DATABASE--INVERSE

INTERFACE


INTERFACEDATABASE

Description DATABASE is a push button in the INTERFACE menu which accessesthe Interface Database. Using ProCAST’s DATABASE FACILITY youmay create, delete, or modify an interface or its properties in theinterface database. These interface descriptions may then be used forsimulation and analysis.

Method DATABASE is activated by clicking on it. This results in the immediateaction to display a table containing any interface descriptions whichmay be in the database. The figure shown here illustrates a display ofthe materials in theInterface Database.

PreCAST allows youto Read, Add, Copy,and Delete interfacedescriptions from theInterface Database. These capabilitiesare described in theDATABASEFACILITY section ofthis manual. Youshould also refer tothe TABLEMAINTENANCEsection of thismanual whichdescribes ProCAST’s graphical interface for maintaining tables.

This section will discuss the requirements for adding an interfacedescription to the database and how you specify individual propertiesand attributes for that interface.

To add an interface description to the database, click on the ADD pushbutton in the Interface Database display. This will result in theimmediate action to open a blank Interface Description and an optionsub-menu which are shown below. Note that PreCAST has entered theUSER name and the DATE for you.

INTERFACE


The minimum requirement for adding an interface description to thedatabase is to give it a KEY or name and define a heat transfercoefficient.

The syntax and options available for the Interface Description arediscussed below.KEY:Enter the name you want to give the new interface description. Sinceyou are describing a coefficient for an activity between two materials, itmay be helpful to enter a key which will be easy for you to remember. For example, you could enter Al, Fe to identify an interface betweenAluminum and Iron or My_Al_SpecialOne, My_Sand for an interfacebetween alloys and materials which you have compounded. The keyword must begin with an alphabetic character and may include upperand lower case characters.

INTERFACE


HEAT TRANSFER COEFFICIENT:PreCAST provides three ways for you to specify the Heat TransferCoefficient for an interface. It may be a constant quantity or a functionof time and/or temperature. As shown in the option sub-menu in thefigure above, these options are: CONSTANT, TIME, orTEMPERATURE, respectively. To select a method, click the leftmouse button when the cursor is over the corresponding push button. This will result in the immediate action to display an additional dialogbox or data input table.

Selecting CONSTANT will open an input box as shown here. Noticethat it has a rotary toggle switch for the units of measure and a textinput line. Select thedesired units ofmeasure by clickingon the UNITS pushbutton. Successiveclicks on this pushbutton will togglethrough the available options.

Select the Interface Coefficient units from the following choices: {W/m**2/K | cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**/F/sec |Btu/in**2/F/sec | cal/cm**2/C/min | Btu**2Fmin | Btu/in**2/F/min}

To enter the desired constant value to be used, move the cursor to thetext input line and type the value. When you click on the APPLY pushbutton, the data entered will be stored, the dialog box will be closed,and the CONSTANT push button on the Interface Description displaywill be highlighted in light blue.


INTERFACE


Rotary Toggle Switch

Selecting the TIME orTEMPERATUREoption will result inthe immediate actionto display theappropriate inputtable. These tables,like the dialog box fora constant, willcontain rotary toggleswitches for the unitsof measure. Asshown in thisexample for TIME,there is a toggleswitch which alsoserves as the columnsub-heading for thetable.

The TIME option allows you to enter the interfacial heat transfercoefficient as a linear function of time.

Select the desired units of measure by clicking on the column headingpush button. Successive clicks on these push buttons will togglethrough the available options. To enter a table value, select the first ornext available table entry, move the cursor to the text input line, type

the value, and press the ENTER key. This will place the value in the

table and move the cursor to the next available table entry.

Select the time units from the following choices: {sec | min}

INTERFACE


When you are satisfied with the table entries, click on the STORE pushbutton, the data in the table will be stored, the dialog box will be closed,and the TIME pushbutton on theInterface Descriptiondisplay will behighlighted in lightblue.

The TEMPERATUREoption allows you toenter the interfacialheat transfercoefficient as a linearfunction oftemperature. Theinput display shownhere will be displayedwhen you select theTEMPERATUREoption.

Select the Temperature units from the following choices: {K | C | F | R}

Select the Interface Coefficient units from the following choices: {W/m**2/K | cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**/F/sec| Btu/in**2/F/sec | cal/cm**2/C/min | Btu**2/F/min |Btu/in**2/F/min}

Enter the temperatures in column one and Interface Coefficient valuesin column two.

When you are satisfied with the table entries, click on the STORE pushbutton, the data in the table will be stored, the dialog box will be closed,and the TEMPERATURE push button on the Interface Descriptiondisplay will be highlighted in light blue.

For either the TIME or TEMPERATURE options, you may click on theGRAPH push button to display a graph of the function. You may clickon the ERASE push button to erase the entire contents of the table. You may click on the CANCEL push button to close the dialog boxwithout saving the data.

INTERFACE


COMMENTS: This portion of the Interface Description is a free formattext box which may be used to annotate the interfacecoefficient. For example, you may want to describe thesources for the data entered or techniques used to develop thedata.

Remarks Interfacial heat transfer coefficient information depends on thematerials involved, the geometry, coating properties and thickness, andon the relative deformation of the part and mold. Normally, this data isacquired by experiment, although some ballpark numbers are availablein the literature.

You may apply the Interface Transfer Coefficient by using combinationsof the CONSTANT, TIME, and TEMPERATURE definitions. You canhave the following combinations: 1. CONSTANT, 2. CONSTANT + TIME, 3. TEMPERATURE, 4. TEMPERATURE + TIME, or 5. TIME.

If you complete and save a TEMPERATURE linear function table, theconstant value will be set to 1.0. If you apply a constant value, even ifit is 1.0, the Temperature Table is abandoned.


INTERFACE


Material 3

Material 2

Material 1Interface

INTERFACECREATE

Description CREATE is a push button in the INTERFACE menu which allows you tocreate interfaces between selected pairs of adjacent materials. Usingthis capability you may create coincident nodes between these adjacentmaterials. Once created, these interface elements may then beassociated with interface descriptions for use in simulation and analysis.

Method CREATE is activated by clicking on it. This results in the immediateaction to display a table listing the material combinations which sharenodes in the geometry is also displayed. The figure shown hereillustrates a geometry and a display which contains two pairs ofadjacent materials.

Creating interface nodes is a three step process.1. Select a material pair for which you want the interface nodes

created. When you click on a material pair, theelements with those material ID’s will be drawn in blueand red in the work window pane. The interface will behighlighted in green. The insert to the figure aboveillustrates these three items in the work window pane.

2. Set the YES--NO toggle switch for the selected pair to YES. Each row in the Adjacent Materials table represents amaterial pair. In the right-most column of each entry isa YES--NO toggle switch. Successive clicks on thisswitch will toggle between YES and NO.

INTERFACE


Coincident Nodes

3. Repeat steps One and Two until all of the desired materialpairs have been set to YES. It is not necessary to setthe switch to YES for every pair shown. However, youmust set the switch to YES for those pairs which shouldhave interface nodes before clicking the EXECUTEpush button.

4. Click on the EXECUTE push button in the AdjacentMaterials display table. EXECUTE will create the newcoincident nodes. These nodes will be displayed as reddots in the work window pane. These new nodes areshown in the example below.

Click on the QUIT push button to close the dialog box.

Remarks The EXECUTE function can only be activated once, not separately foreach pair. Execute generates an extra set of nodes at the interface andautomatically reorganizes the element connectivities. Once theinterface nodes have been created, you can not go back and rearrangeyour interface selections. The only way to change these interfaceselections is to start over with a new copy of the initial geometry.

Filters do not need interfaces between the fluid and filter. If you createsuch an interface, the fluid will not flow through the filter.

Related Topics TABLE MAINTENANCE

INTERFACE


INTERFACEASSIGN

Description ASSIGN is a push button in the INTERFACE menu. It provides thecapability to associate heat transfer coefficients from the database withelement ID’s in the model.

Method ASSIGN is activated by clicking on it. This results in the immediateaction to display a table containing a list of the material pairs betweenwhich exist interface nodes. The first column of this list will containeither a C to indicatethat the nodes in thispair are Coincident oran N to indicate thatthey are Non-coincident.

A table of the heattransfer coefficientsin the InterfaceDatabase is alsodisplayed. The figureshown here illustratesa display for a modelwhich contains onepair of materials withinterface nodes.

As you click on oneof the material IDs inthe pair, the twomaterials are drawnin blue and red in thework window pane.

INTERFACE


To assign an interface coefficient:1. Select an entry from the Material Pairs DB list by clicking on the

desired table entry. The selected entry will be highlighted inred.

2. Select an interface from the database by moving the cursor down tothe window displaying the INTERFACE DATABASE entries. Ifthe interface you want is not visible in the table at first, you mayscroll to the desired entry.

3. When you have located the desired interface entry, click on it.4. ASSIGN the interface to the material pair by clicking the ASSIGN

push button. This will place the interface database sequencenumber in the DB ENTRY column of the MATERIAL PAIRS DBdisplay. In the figure above, notice that the number “5" hasbeen placed in this column because it corresponds to theselected interface database table entry “Clay, Sand.”

To associate interface coefficients with other material pairs, repeatsteps one through four.

ADD is used for creatinginterfaces between non-aligning meshes. As shownin the figure here, the nodesin Material 7 and Material 6do not align. Therefore,when you click on the ADDpush button, an input dialogbox will open. In this dialogbox, you specify the twomaterial numbers for which you want to add and assign an interface. The ADD capability is also used to define the interface between a fluidand a filter.

DELETE is used to delete any unwanted interfaces.

When you are satisfied with the assignments, click on the QUIT pushbutton in the Material Pairs DB table display or click on a push button inthe Main Function Banner. This will store the assignments and closethe display.

Remarks The order of the material IDs in each row of the Material Pairs displaytable is significant. If the interface coefficient to be assigned is afunction of temperature, PreCAST will use the surface temperature ofthe first material ID in the row.

You may flip the sequence of the material IDs by clicking on the secondID. Doing so changes the position of the material IDs, however it doesnot change the materials or the interface. In the figure shown above,

INTERFACE


clicking on the number “3" would move it to the column which nowcontains a “2" and the “2" would be moved to the column which nowcontains the “3.” The column which was clicked last remainshighlighted in red.

If you delete an interface, the mesh will not be changed. However,there will not be any interface coefficient assigned.

If you intended the interface to be non-coincident and it happens toalign, you must delete the interface and re-add it to the model.

You may examine and/ormodify the interfacecoefficients in the InterfaceDatabase entries by clickingthe READ/MODIFY pushbutton in the InterfaceDatabase display window. This will display the InterfaceDescription Display as shownhere.

Related Topics DATABASE FACILITY,TABLE MAINTENANCE,INTERFACE--CREATE

INTERFACE


INTERFACEMULTI-POINTS

Description MULTI-POINTS is a push button in the INTERFACE menu which allowsyou to describe thermal constraints between element regions whennodes do not align. The temperatures of the nodes on one side of amulti-point interface are forced to be a linear combination of the nodaltemperatures on the other side of the interface. Using this capabilityyou specify tolerances which are used in the search for constrainingnodes. Once identified, the weighting factors are computedautomatically from the geometry by PreCAST.

Multi-points can only be used in a thermal solution or in the mold offluids analysis. This is because pressure gradients are not wellbehaved across a multi-point interface.

Method MULTI-POINTS is activated by clicking on it. This results in theimmediate action to display a table listing the possible combinations ofmaterials between which multi-point constraints could be created.

In the Material Combinations display, “M” and “S” stand for master andslave IDs. The slave nodes will be constrained by the master nodes. Generally, you would want the coarser mesh to be the master side.

You may flip the material IDs, thereby changing the designation of themaster side, by clicking on the ID you want to be the master side. Doing so changes the position of the material IDs, however it does notchange the materials or the interface. In the figure shown above,clicking on the number “1", in row one column two, would move it to thecolumn which now contains a “2" and the “2" would be moved to thecolumn which now contains the “1.” Accordingly, in this example,material “1" would now be designated as the master side.

INTERFACE


Creating multi-point interface constraints is a five step process.1. Identify a material pair for which you want the interface

constraint created. If you click on a material ID in the“M”aster column, the elements with those ID’s will bedrawn in red in the work window pane.

2. Set the YES--NO toggle switch for the selected pair to YES. Each row in the Material Combinations table representsa material pair. The third column of each entry is aYES--NO toggle switch. Successive clicks on thisswitch will toggle between YES and NO.

3. Set the PLANE and PERIMETER tolerances to be used inthe search for constraining nodes.

4. Repeat steps One through Three until all of the desiredmaterial pairs have been set to YES. It is notnecessary to set the switch to YES for every pairshown.

5. Click on the EXECUTE push button in the MaterialCombinations display table. EXECUTE will calculatethe weighting factors. The master nodes will bedisplayed in red and the slave nodes will be displayedin green in the work window pane.

To change the PLANE and/or PERIMETER tolerance, select thedesired table value by clicking the left mouse button when the cursor isover the tolerance in the table. This will cause the value to behighlighted in red. Move the cursor to the Edit Value line. Type thenew tolerance and press ENTER. This will place the new value in thetable entry.

Click on the QUIT push button to close the dialog box.

Remarks A multi-point interface is not like a thermal break interface because noheat transfer coefficient is involved. You must assign a differentmaterial ID to the elements on either side of the interface, even if theywill be assigned the same material properties.

A multi-point and a coincident node interface cannot be createdbetween the same material ID pair. Therefore, any material ID pairswhich were selected for coincident node interfaces will not appear in theMaterial Combinations table display.

INTERFACE


Node“In-the-Plane” Tolerance

Element Face“Perimeter” Tolerance

Node

PLANE and PERIMETER give tolerances which are used in the searchfor constraining nodes. PLANE is a tolerance normal to the plane of theinterface. PERIMETER is the distance outside the edge of an elementface that a slave node can be and still be constrained by the nodes inthat face. This is illustrated in the figure shown here.

Related Topics INTERFACE--CREATE, TABLE MAINTENANCE

INTERFACE


Example As an example of the use of the multi-point constraints, the followingtwo figures are sketches of the finite element mesh above (shown onthe right) and below the multi-point constraint interface plane (shown onthe left).

Y

XMetal

Bottom Element Layout

Y

XMold

Top Element Layout

The mesh has been created such that the metal elements will becontiguous through the intersection. Therefore, no multi-pointconstraints need be generated for the metal. The mold elements oneither side of the plane will have to be linked by multi-point constraints. Normal to the multi-point interface plane there will be a coincident nodeinterface between the metal and the mold. Some care needs to betaken while performing nodal equivalencing so that the metal nodes arecombined but the mold nodes are not.

INTERFACE


INTERFACEINVERSE

Description INVERSE is a push button in the INTERFACE menu which allows youto select the interfaces in the model for which the heat transfercoefficients will be calculated using the inverse calculation method.

Method INVERSE is activated by clicking on it. This results in the immediate action todisplay a table listing the coincident andnon-coincident interfaces. The figureshown here illustrates this display.

As shown in this figure, the column on theright side of the table has the headingindicating the heat transfer coefficient--H. Beneath this heading is a toggle switch. There is one switch in each row of thetable and corresponds to each set ofdefined interfaces in the database. You specify the interfaces whichare to be calculated using the inverse method by toggling the

corresponding switch to the Y or yes position.


Remarks Using the inverse method for calculating an interface heat transfercoefficient may be used in conjunction with Boundary Condition--Inverse. However, it can not be used in conjunction with Materials--Inverse.

The initial guess for the calculated interface coefficient is taken as thedatabase value that has been assigned.

Related Topics INTERFACE

BOUNDARY CONDITIONS


BOUNDARY

Description BOUNDARY is a push button in the Main Function Banner. Thisfunction of PreCAST enables you to describe boundary conditions andtheir properties in the database. It also enables you to assign boundaryconditions to element faces, nodes, and material IDs in the model. When you activate the BOUNDARY CONDITIONS push button, amenu is opened which allows you to work with the various capabilitiesassociated with Boundary Conditions. Selections from the menuprovide access to these capabilities and will be discussed in thissection.

Method BOUNDARY is activated by clicking on it. The initial menu is shownhere. When you select a function fromthis menu PreCAST will displayadditional Dialog Boxes, Option Lists,Data Input Windows, or sub-menus. These graphical interface tools will guideyou through the process of specifying,changing or deleting information aboutthe boundary conditions in the database. These may be used in your model and

the analysis to be performed.

You may leave the BOUNDARY CONDITIONS function by clickinganother push button in the Main Function Banner.

Remarks The major capabilities of the BOUNDARY CONDITIONS function ofPreCAST will be summarized here. Each capability will be described ingreater detail in this manual.DATABASE

Provides the data management functions for the boundaryconditions and their respective properties or attributes in yourdatabase. DATABASE allows you to add, delete, copy, andmodify entries in the boundary condition database.

ASSIGN SURFACEProvides the capability to select element faces or nodes,combine them into sets, and assign boundary conditions toeach set.

ASSIGN VOLUMEProvides the capability to assign heat, momentum, mass, orcurrent density to particular material regions.

BOUNDARY CONDITIONS


PERMEABILITYProvides the capability to account for the trapped gas whichescapes through the mold. This is intended primarily for sandor shell molds.

INVERSEProvides the capability to configure the problem to use theinverse calculation method for the determination of HEATboundary conditions: film coefficient, heat flux, or emissivity.

When you select from the BOUNDARY CONDITIONS menu, additionalsub-menus, input displays, and dialog boxes will be displayeddepending upon the function you have selected.

ProCAST’s graphical user interface provides a straight forward andsimple procedure for working with the various databases used byProCAST. This database facility is described elsewhere in this manual. You should read about this facility before attempting to modify thematerials database.

Each of the Boundary Condition menu choices will be described in thissection.

Related Topics DATABASE FACILITY

BOUNDARY CONDITIONS


BOUNDARYDATABASE

Description DATABASE is a push button in the BOUNDARY menu which accessesthe Boundary Condition Database. Using ProCAST’s DATABASEFACILITY you may create, delete, or modify a boundary condition or itsproperties in the boundary conditions database. These boundarycondition descriptions may then be used for simulation and analysis.

Method DATABASE is activated by clicking on it. This results in the immediateaction to display a table containing any boundary conditions which maybe in the database. The figure shown here illustrates such a display.

PreCAST allows youto Read, Add, Copy,and Delete boundaryconditions from theBoundary ConditionDatabase. Thesecapabilities aredescribed in theDATABASEFACILITY section ofthis manual. Youshould also refer tothe TABLEMAINTENANCEsection of thismanual whichdescribes ProCAST’sgraphical interfacefor maintainingtables.

This section will discuss the requirements for adding a boundarycondition to the database and how you specify individual properties andattributes for that condition.

To add a boundary condition to the database, click on the ADD pushbutton in the Boundary Condition Database display. This will result inthe immediate action to open a sub-menu which lists the types ofconditions which may be described. This sub-menu is shown below.

BOUNDARY CONDITIONS


The characteristics, properties,and options which are availableor required vary from oneBoundary Condition to another.

When you choose from thismenu, ProCAST will display theappropriate input form andoptions in a blank BoundaryCondition Description which isshown below. For convenienceof illustration, the example shownis the result of selecting theCURRENT DENSITY option fromthe sub-menu.

PreCAST also displays an optionbox above the BoundaryCondition Description display. The content of the option boxdepends upon the type ofboundary condition you selected. The option box may containproperties or options which aredisplayed as a group of checkboxes, push buttons, text input

lines, or a combination of these. In this case, the current density maybe designated as a CONSTANT or as a linear function of TIME. Therefore, there are corresponding push buttons in the option box.

If the option box includes atext input line, enter data ina text input line by placingthe cursor in the text box,typing the desired data,

and pressing ENTER. In

some cases, the text inputline will be accompaniedby a rotary toggle switch. These toggle switchesallow you to choose thedesired value from a list ofoptions. Successive clickson the toggle switch willcycle through the availableoptions.

Note that PreCAST has entered the USER name and the DATE for you.

BOUNDARY CONDITIONS


PreCAST has also entered, as a default, the KEYWORD which is thesame as the file prefix you entered when you started PreCAST. Theminimum requirement for adding a boundary condition to the databaseis to give it a keyword name. All of the boundary condition descriptionshave two input text lines in common: KEYWORD and COMMENTS.

The syntax for the common entries are described below. Followingthese descriptions, the individual options for each available boundarycondition are discussed.

KEYWORD: Enter the name you want to give the boundary conditiondatabase entry. The boundary condition keyword must beginwith an alphabetic character and may include upper and lowercase characters.

COMMENTS: This portion of the Boundary Condition Description is afree format text box which may be used to annotate theboundary condition. For example, you may want to describethe sources for any property data or techniques used to developthe boundary condition or its properties.

To specify a property which is displayed in a check box, click on thedesired property’s check box. This will result in the immediate action todisplay an additional option menu ora input dialog box. Some propertiesmay be specified either as constantsor as a linear function. An optionmenu, similar to the one shown here, will allow you to select theproperty as either a CONSTANT or as a function of TIME, PRESSURE,FLOW RATE, or TEMPERATURE.

ProCAST dynamically displays the appropriate property names, optionboxes, and input text lines based upon the type of boundary conditionoption you select.

If you select the CONSTANT option, an input box similar to the oneshown here will be displayed. It will contain a text input line and maycontain a rotarytoggle switch for theunits of measure. Successive clicks onthis push button willtoggle through theavailable options. To enter the desired value for this property orattribute move the cursor to the text input line and type the value.

BOUNDARY CONDITIONS


When you click on the APPLY push button or press ENTER, the data

entered will be stored, and the dialog box will be closed.

You may click on theCANCEL push buttonto close the dialogbox without savingthe data.

Selecting otheroptions usuallyresults in theimmediate action todisplay an inputtable. This table, likethe dialog box for aconstant, maycontain rotary toggleswitches for the unitsof measure. Asshown in thisexample for SurfaceLoad, there are twotoggle switches which also serve as the column sub-headings for thetable.

Select the desired units of measure by clicking on the column headingpush buttons. Successive clicks on these push buttons will togglethrough the available options. To enter a table value, select the first ornext available table entry, move the cursor to the text input line, type


table and move the cursor to the next available table entry. When youare satisfied with the table entries, click on the STORE push button, thedata in the table will be stored, and the dialog box will be closed.


The method, syntax, and options for each Boundary Condition will bepresented below. For convenience of presentation, they are presentedin alphabetical order.

BOUNDARY CONDITIONS


CURRENT DENSITYis used to define the current density flowing through an induction coil.

You may enter thecurrent density as aconstant or as afunction of time. Thetime functionmodifies the constantvalue specified. Accordingly, if youuse the TIME option,the constant valueyou provide will beused. The defaultconstant value is 1.0.

Negative values ofcurrent density willreverse the currentflow.

For a 2Delectromagnetics problem, a positive value of current density isassumed to flow out of the plane of the model towards the viewer. Fora 3D problem, a positive value of current density is assumed to flow inthe t or last parametric direction of an element. This type of definition,restricts the construction of the induction coils. These coils must becomposed of either hex or wedge elements only. Tetrahedron elementscan not be used. Negative values of current density will reverse thecurrent flow.

Constant: Select the Current Density units from the following:{amps/m**2 | amps/cm**2 | amps/mm**2 | amps/ft**2 |amps/in**2}

Enter the constant value to be used in the input line.Function of time: Select the time units from: {sec | min}

Select the Current Density units from the following:{amps/m**2 | amps/cm**2 | amps/mm**2 | amps/ft**2 |amps/in**2}

Enter the time values in column one and currentdensity values in column two.

BOUNDARY CONDITIONS


DISPLACEMENTIs used to define the x, y, z displacement constraints for a stress

problem. You mayenter thedisplacement as aconstant or as afunction of time. Thetime functionmodifies the constantvalue specified. Accordingly, if youuse the TIME option,the constant valueyou provide will beused. The defaulttime value constantis 1.0.

The defaultDISPLACEMENTsetting is NoConstraint becauseyou may wish toconstrain only onedirection.

Displacement can be constrained in any or all coordinate directions. The units selected will be applied to all constraint coordinate directions.

Constant: Select the Displacement units from the following: {m |cm | mm | ft | in}

Enter the constant value to be used in each of theappropriate (X:, Y:, and Z:) input lines.

Function of time: Select the time units from: {sec | min}Select the Displacement units from the following: {m |cm | mm | ft | in}

Enter the time values in column one and displacementvalues in column two.

BOUNDARY CONDITIONS


HEATIs used to define heat flux boundary conditions applied to element

faces. Theseconditions may be acombination ofprescribed heat flux,convection, andradiation. This isknown, by some, asthe Cauchy condition.

When you selecteither the FLUX orthe AMBIENT TEMPcheck box, you willpresented with anadditional optionmenu from which youmay choose to enter

values for these characteristics as a constant or as a function of time. When you select either the FILM COEFF or the EMISSIVITY checkbox, you will be presented with an additional option menu from whichyou may choose to enter values for these characteristics as a constant,a function of time, and/or a function of temperature.

AMBIENT TEMP--indicates the temperature of the environmentsurrounding the model and is used to calculate the convectiveand/or radiation heat transfer. See Equations C.8.10 andC.8.11 in Appendix C.Constant: Select the Temperature units from the following: {C |

F | R | K}


Select the Temperature units from the following: {C | F |R | K}

Enter the time values in column one and temperaturevalues in column two.

BOUNDARY CONDITIONS


EMISSIVITY--indicates the radiation of heat and is used to calculateradiative heat transfer. See Equation C.8.11 in Appendix C. This value should be between 0 and 1.Constant: Enter the constant value to be used in the input line.

Function of time: Select the time units from: {sec | min}

Enter the time values in column one and emissivityvalues in column two.

Function of temperature: Select the Temperature units fromthe following: {C | F | R | K}

Enter the temperature values in column one andemissivity values in column two.

FILM COEFFICIENT--indicates the value of heat transfer and is used tocalculate convective heat transfer. See Equation C.8.10 in Appendix C.

Constant: Select the film units from: {W/m**2/K |cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**2/F/sec |Btu/in**2/F/sec | cal/cm**2/C/min | Btu/ft**2/F/min |Btu/in**2/F/min}


Select the film coefficient units from: {W/m**2/K |cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**2/F/sec |Btu/in**2/F/sec | cal/cm**2/C/min | Btu/ft**2/F/min |Btu/in**2/F/min}

Enter the time values in column one and filmcoefficient values in column two.

Function of temperature: Select the Temperature units fromthe following: {C | F | R | K}Select the film coefficient units from: {W/m**2/K |cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**2/F/sec |Btu/in**2/F/sec | cal/cm**2/C/min | Btu/ft**2/F/min |Btu/in**2/F/min}

Enter the temperature values in column one and filmcoefficient values in column two.

BOUNDARY CONDITIONS


FLUX--indicates heat transfer in or out of the model. See EquationC.8.9 in Appendix C.

Constant: Select the flux units from: {W/m**2/sec |cal/cm**2/sec | cal/mm**2/sec | Btu/ft**2/sec |Btu/in**2/sec | cal/cm**2/min | Btu/ft**2/min |Btu/in**2/min}


Select the flux units from: {W/m**2/sec | cal/cm**2/sec| cal/mm**2/sec | Btu/ft**2/sec | Btu/in**2/sec |cal/cm**2/min | Btu/ft**2/min | Btu/in**2/min}

Enter the time values in column one and flux values incolumn two.

VIEW FACTOR--is a toggle switch which cycles between ON and OFF. This switch indicates whether or not the element faces that willbe assigned this data set will be participating in the view factorcalculations. Note: If VIEW FACTOR is ON, then theemissivity must be given in this set. If VIEW FACTOR is OFFand the emissivity is specified, then the ambient temperaturemust also be input.

BOUNDARY CONDITIONS


INJECTIs used to define the mass flow rate of a gas injection port to be

attached to selectednodes in the voidregion of a castingmodel. This data isused with the trappedgas model for freesurface flow todevelop a gas over-pressure for drivingthe liquid metal.

The mass flow ratecan be given as aconstant, a functionof time, or a functionof the back pressurethat develops fromthe trapped gas.

Constant: Select the Mass Flow Rate units from: {kg/sec | g/sec | lb/sec | kg/min | g/min | lb/min}


Function of time: Select the time units from: {sec | min}Select the Mass Flow Rate units from: {kg/sec | g/sec | lb/sec | kg/min | g/min | lb/min}

Enter the time values in column one and mass flow ratevalues in column two.

Function of pressure: Select the Pressure units from thefollowing: {atm | psia | Ksi | lb/ft**2 | N/m**2 | Pa | KPa |MPa | bar | dyne/cm**2}Select the Mass Flow Rate units from: {kg/sec | g/sec | lb/sec | kg/min | g/min | lb/min}

Enter the pressure values in column one and mass flowrate values in column two.

BOUNDARY CONDITIONS


MAGNETIC POTENTIALIs used to define the prescribed magnetic potential to be applied toselected nodes inthe model. Thistype of boundarycondition is used toset the far-fieldcondition for anelectromagneticanalysis. Normally,the potential is set tozero all along theouter boundary of amodel. Meshregions should beextended far enoughfrom the inductioncoils so that the far-field condition issatisfied.

You may enter theMagnetic Potential as a constant or as a function of time.

Constant: Select the Magnetic Potential units from thefollowing: {weber/m, weber/cm, weber/mm, weber/ft,weber/in}


Select the Magnetic Potential units from the following:{weber/m, weber/cm, weber/mm, weber/ft, weber/in}

Enter the time values in column one and magneticpotential values in column two

BOUNDARY CONDITIONS


MASS SOURCEIs used to define a fluid mass source. Mass sources can be used to

create a source offluid without explicitlymodeling that sourcein finite elements. Mass sources canmove around insidethe model, allowingthings like retractablenozzles to bemodeled.

To define a MassSource you providethe sourcetemperature, the flowrate, and the x, y, z

coordinate position. The source temperature, flow rate, and coordinate position can begiven as a constant or a function of time.

TEMPERATUREConstant: Select the Temperature units from: {C | F | R | K}


Select the Temperature units from: {C | F | R | K}


FLOW RATEConstant: Select the Flow Rate from: {kg/sec | g/sec | lb/sec |

kg/min | g/min | lb/min}


Select the Flow Rate units from the following: {kg/sec | g/sec | lb/sec | kg/min | g/min | lb/min}

Enter the time values in column one and flow ratevalues in column two.

BOUNDARY CONDITIONS


X, Y, Z

Constant: Select the units from: {m | cm | mm | ft | in}


Select the units from: { m | cm | mm | ft | in}

MOMENTUM SOURCEIs used to define a fluid momentum source which will impose apressure gradient. Momentum sourcescan be used to createfluid motion withoutrequiring the objectresponsible for thatmotion to beexplicitly modeled infinite elements. Youmay enter themomentum source asa constant or as afunction of time.

Using the X, Y, Zcoordinates, you canspecify the directionfor a momentumsource. Direction canbe in any or allcoordinate directions. The units selected will be applied to all constraint coordinate directions.

Constant: Select the Source Strength units from the following:{N/m**3, dyne/cm**3, lb/ft**3, lb/in**3}


Function of time: Select the time units from: {sec | min}Select the Source Strength units from the following:{N/m**3, dyne/cm**3, lb/ft**3, lb/in**3}

Enter the time values in column one and sourcestrength values in column two.

BOUNDARY CONDITIONS


POINT LOADis used in stress problems to define the x, y, and z loads at a point.

You may enter the point load as a constant or as a function of time.

The components of a force vector are defined using X, Y, Zcoordinates. The units selected will be applied to all coordinatedirections.

Constant: Select the Point Load units from the following: {dyne |Newton | lb}


Function of time: Select the time units from: {sec | min}Select the Point Load units from the following: {dyne |Newton | lb}

Enter the time values in column one and point loadvalues in column two.

BOUNDARY CONDITIONS


PRESSUREis used to define the prescribed pressure to be applied to selectednodes.

You may enter the Pressure as a constant or as a function of time.

Constant: Select the pressure units from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia | Ksi | lb/ft**2}


Select the pressure units from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia | Ksi | lb/ft**2}

Enter the time values in column one and pressurevalues in column two.

BOUNDARY CONDITIONS


SURFACE LOADis used in stress problems to define the x, y, and z loads at a surface.

You may enter the surface load as a constant or as a function of time.

The components of a force vector are defined using X, Y, Zcoordinates. The units selected will be applied to all coordinatedirections.

Constant: Select the Point Load units from the following: {atm,psia, Ksi, lb/ft**2, N/m**2, Pa, KPa, MPa, bar,dyne/cm**2}


Function of time: Select the time units from: {sec | min}Select the Point Load units from the following: {atm,psia, Ksi, lb/ft**2, N/m**2, Pa, KPa, MPa, bar,dyne/cm**2}

Enter the time values in column one and surface loadvalues in column two.

BOUNDARY CONDITIONS



SURFACE NUCLEATION

Editor’s Note: The Surface Nucleation boundary condition capability has not yet beenimplemented in ProCAST.

When you select the SURFACE NUCLEATION menu option, the dialogbox shown here will be displayed.

BOUNDARY CONDITIONS


TEMPERATUREis used to define the prescribed nodal temperatures. Mathematically,this is known as a Dirichlet condition.

You may enter the Nodal Temperature as a constant or as a function oftime.

Constant: Select the temperature units from: {C | F | R | K}


Select the temperature units from: {C | F | R | K}


BOUNDARY CONDITIONS


TURBULENCEIs used to define the turbulence quantities of intensity and characteristic

length to be assignedto mass inflow nodes. This boundarycondition is used withthe �---� turbulencemodel for highReynolds numberflows.

When you selecteither theINTENSITY or theCHARACTERISTICLENGTH check box,you will be presentedwith an additionaloption menu fromwhich you maychoose to entervalues for these

characteristics as a constant or as a function of time.

INTENSITY--indicates a fraction of the bulk velocity. It is the size ofthe current eddy as compared to the main stream.Constant: Enter the constant value to be used in the input line.

The default is .1 (10%).

Function of time: Select the time units from: {sec | min}

Enter the time values in column one and intensityvalues in column two.

CHARACTERISTIC LENGTH--specifies the length, usually, of theopening through which the stream is flowing. The characteristiclength is usually the smallest dimension of the channel.Constant: Select the length units from: {m | cm | mm | ft | in}


Function of time: Select the time units from: {sec | min}Select the length units from: {m | cm | mm | ft | in}

Enter the time values in column one and characteristiclength values in column two.

BOUNDARY CONDITIONS


VELOCITYIs used to define a prescribed velocity to be applied to selected nodes.

Velocity can be usedto describe the FillingRate. If the velocityis specified as zero itcan be used todescribe a non-slipboundary condition.

For a 3D model, youspecify the threecomponents of thedirection of thevelocity by enteringvalues in the U, V,and W input lines. Ifyou leave one ofthese input linesblank, it does notdefault to a value ofzero.

For a 2D model, youspecify the U and Vcomponents of thisdirection, the Wcomponent, if

entered, is ignored.

Even though the total magnitude of the velocity may be modified byfunctions of time and/or pressure, you are required to provide thesecomponents to indicate the orientation of the velocity vector.

Leaving one or more of the U, V, and W slots blank does not result in adefault value of zero. This is because of certain situations that arisewhen it is necessary to constrain only one component by itself. For aninlet flow particularly, all three components must be given.

The TIME and PRESSURE functions allow you to input functions oftime and pressure which modify the velocity magnitude. For example,you might want to give a pressure function which sets an inlet velocityto zero if the pressure exceeds a certain value. This situation mightoccur if you tried to over fill a casting.

To calculate an inlet velocity magnitude; take the total volume of thecasting and rigging and divide it by the fill time to yield an inlet flowrate. Then divide the inlet flow rate by the inlet area to give the velocity

BOUNDARY CONDITIONS


magnitude. One subtle point to be aware of is that ProCAST includesin the inlet area total, the areas of any face that has at least one nodeassigned to the inlet velocity.

Selecting the TIME and PRESSURE push buttons will open tabledisplays which will allow you to input these functions.

Constant: Select the velocity units from the following: {m/sec |ft/sec | in/sec | m/min | cm/min | ft/min | in/min}

Enter the constant value to be used in each of theappropriate (U:, V:, and W:) input lines.

Function of time: Select the time units from: {sec | min}Select the velocity units from the following: {m/sec |ft/sec | in/sec | m/min | cm/min | ft/min | in/min}

Enter the time values in column one and velocityvalues in column two.

Function of pressure: Select the pressure units from: {N/m**2 |Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia | lb/ft**2}Select the velocity units from the following: {m/sec |ft/sec | in/sec | m/min | cm/min | ft/min | in/min}

Enter the pressure values in column one and velocityvalues in column two.

FILL LIMIT is a slider which allows you to specify, as a percent of full,when an inlet flow should be turned off. For example, if the fill limit isset to 99, the inlet velocity will be set to zero magnitude when thecasting is 99% full.

You may adjust the FILL LIMIT by clicking the left mouse button oneither the right or left arrows, by clicking and dragging the slider knob tothe desired position, or by clicking the left mouse button when thecursor is positioned over the slider’s track.

A FILL LIMIT boundary condition affects the specific inlet to which it isassigned. In the RUN PARAMETERS you may set the LVSURFparameter to turn off all inlets in the model.

BOUNDARY CONDITIONS


VENTIs used to describe a vent which can be attached to selected nodes on

the casting side ofthe mold-metalinterface. VENT isused with the trappedgas model for freesurface flow duringfilling transients.

The vent diameter,effective length, andsurface roughness allhave units of lengthwhich can be setindependently. Youclick on the EXITPRESSURE checkbox to provide thecapability to specifythe pressure as eithera constant or as afunction of time.

Select the Diameter, Length, Roughness units from: {m | cm |mm | ft | in}

Enter the constant value to be used in each of theappropriate input lines.

Constant: Select the Pressure units from: {atm | psia | Ksi |lb/ft**2 | N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2}

Function of time: Select the time units from: {sec | min}Select the Pressure units from: {atm | psia | Ksi | lb/ft**2| N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2}

Enter the time values in column one and exit pressurevalues in column two.

BOUNDARY CONDITIONS


VOLUMETRIC HEATIs used to define a volumetric heat source or sink. A positive value isused to describe aheat source and anegative value todescribe a heat sink.

You may specify theVolumetric Heat as aconstant or as afunction of TIMEand/orTEMPERATURE.

The time functionmodifies theconstant valuespecified. Accordingly, if youuse either of theseoptions, the constantvalue you providewill be used. Thedefault constant value is 1.0.

Constant: Select the Volumetric Heat units from: {W/m**3 |cal/cc/sec | Btu/ft**3/sec | Btu/in**3/sec | cal/cc/min |Btu/ft**3/min | Btu/in**3/min}


Enter the time values in column one and heat modifiervalues in column two.

Function of temperature: Select the Temperature units from:{C | F | R | K}

Enter the temperature values in column one and heatmodifier values in column two.

Remarks None.


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BOUNDARYASSIGN SURFACE

Description ASSIGN SURFACE is a push button in the BOUNDARY menu. Itprovides the capability to select element faces or nodes, combine theminto sets, and associate properties from the boundary conditiondatabase with these sets in the model.

Method ASSIGN SURFACE is activated by clicking on it. This results in theimmediate action to display a table containing a list of any boundarycondition node or face sets which have been defined in the model andtheir Boundary Conditionassignment, if any.

Some boundaryconditions are applied tonodes, others to faces. A Boundary ConditionSet may contain nodesor faces but not both. PreCAST selects nodesor faces according to theBoundary Conditiontype.

ASSIGN SURFACE alsodisplays a table of theboundary conditions inthe database. Thesetwo table displays areseparated by a group oftools with which you mayselect element faces andnodes and create groupsets. The figure shownhere illustrates a displayfor a model with severalgroup sets, the Toolbox,and the BoundaryCondition Databaseentries.

BOUNDARY CONDITIONS


The background of a table entry, in either table, will be highlighted inred when it is selected. Group sets or element faces will be drawn inred in the work window pane when their respective set entry is selected.

If you created boundary condition sets in the mesh generation package,such as PATRAN or IDEAS, these sets would appear in the top tabledisplay.

To assign a boundary condition to a group set:1. Select the set by clicking the desired entry in the Assignment Table.2. Select a boundary condition from the database by moving the cursor

down to the window displaying the Boundary ConditionDatabase entries. If the Boundary Condition you want is notvisible in the table at first, you may scroll to the desired entry.

3. When you have located the desired boundary condition entry, clickon it.

4. ASSIGN the boundary condition data to the group by clicking theASSIGN push button in the Toolbox. This will place theBoundary Condition key word and ID# in column two of theAssignment Table.

To associate boundary conditions with other group sets or elementfaces, repeat steps one through four.

PreCAST also provides the capability to create boundary condition sets. The Toolbox contains the tools you use to create these boundarycondition sets. Each tool is represented in the Toolbox as a pushbutton, which may be activated by clicking the left mouse when thecursor is over the corresponding tool. Each of these tools will bedescribed here. For convenience of presentation, they will be describedin alphabetical order.

BOUNDARY CONDITIONS


ADD--creates a Boundary Conditiongroup set entry in theAssignment Table. Whenthis tool is selected, it opensa menu, as shown here,listing each type of boundarycondition.

Select the type of boundarycondition to be described byclicking on the desiredcondition. Clicking on achoice from this menu willresult in the immediate actionto create an entry in theAssignment Table and closethe menu. In the figureshown above, item numbersix, Turbulence, was added tothis table because thecorresponding choice wasmade from the menu at theright.

It is important to note, that atthis point in the process agroup set entry has beencreated in the assignmenttable. However, nodes orfaces have not yet beenassigned to this entry and noboundary condition propertieshave been assigned.

Each of these boundary conditions and their respectiveproperties are discussed in the Boundary Conditions Section ofthis manual.

ASSIGN--associates a boundary condition database entry with aspecific boundary condition group set. To make anassignment, follow the four step procedure described above. Please note that the type of data that you select from thedatabase must agree with the type of group set.

BOUNDARY CONDITIONS


COPY--enables you to copy the contents of one group set to another. This is useful, for example, when you want to applytemperature and velocity conditions to the same nodes. Tocopy a group set, click on the group set table entry you want tocopy and then click on the COPY push button.

There are some restrictions on the COPY operation, dependingupon the type of sets involved. You may copy from any nodalboundary condition set to any other nodal set or from anyelement face boundary condition set to any nodal set. However, you may not copy from nodal sets to face sets.

DELETE--removes a Boundary Condition group set entry from theAssignment Table. To remove a group set, select the desiredentry in the Assignment Table by clicking on it. This willhighlight the selected entry in red. Once the desired set entryhas been highlighted, click on the DELETE push button. Thiswill remove the entry from the table and remove the associationof any nodes which were stored in this entry. DELETE does notremove nodes from the model.

DESELECT--provides the capability to untag faces or nodes in amanner similar to the selection process. To deselect faces ornodes, click on the DESELECT push button. Then drag thecursor over the desired nodes or faces while holding the leftmouse button down. You may also create a drag box toenclose a portion of the model by depressing and holding theright mouse button while dragging the cursor to form a boxaround the desired portion of the model. The SURFACE optionwill also work for deselection.

INTERFACE--provides the capability to tag all faces which are on theinterface. This is particularly helpful in die casting for selectinginner surfaces.

LINK--provides the capability to establish the relationship between twoPERIODIC boundary condition node sets. LINK is used aftertwo PERIODIC node sets have been created (using the ADDtool) and after nodes have been assigned to each of theseentries.

To LINK two PERIODIC node sets, select one of the sets fromthe Assignment Table by clicking on it. The selected entry willbe highlighted with a red background. Next, click on the LINKpush button in the toolbox. The push button will be highlightedwith a red background. Move the cursor to the AssignmentTable and select the companion set. The second table entrywill be highlighted with a green background and PreCAST will

BOUNDARY CONDITIONS


display a Rotation and Transformation Input Display. This isillustrated in the figure shown here.

In the input lines, enter the X, Y, and Z coordinates of twopoints which define an axis of rotation and give the rotationangle in degrees.

You can also input a translation vector by entering thecoordinates of the translation in the DX, DY, and DZ input lines.

Click on the EXECUTE push button in the input display andPreCAST automatically computes a tolerance value basedupon the geometry and determines if the nodes of the two setsmatch up with the specified transformation.

REMAINDER--allows you to tag any free faces which are not a part ofany other similar boundary condition.

SELECT--allows you to tag surfaces for assignment to a boundarycondition set. To select faces or nodes, click on the SELECTpush button after clicking on the intended boundary conditionset in the Assignment Table.

To select faces or nodes, drag the cursor over the desiredsurfaces or node(s) while holding the left mouse button down. You may also create a drag box to enclose a portion of themodel by depressing and holding the right mouse button whiledragging the cursor. Once a surface has been selected, itsedges will be highlighted in red in the work window pane andthe STORE push button in the Toolbox will be highlighted witha blue background to indicate that some faces have beenselected but not stored.

When triangular faces are selected, the centroid is indicatedwith a red dot. When quadrilateral faces are selected, thediagonals are drawn in red.

SELECT ALL--tags all of the external faces or nodes in the problem .

BOUNDARY CONDITIONS


Once a face or node has been selected, its edges will behighlighted in red in the work window pane and the STOREpush button in the Toolbox will be highlighted with a bluebackground to indicate that some faces have been selected butnot stored. Any faces which were previously assigned to aSYMMETRY set will not be tagged by SELECT ALL.

Before using SELECT ALL, you should click on the boundarycondition set in the Assignment Table where you intend toSTORE the selected surfaces or nodes.

STORE--places the selected surfaces or nodes into a boundarycondition set in the Assignment Table. Once you have taggedall the faces or nodes that you want to be in the set, click on theSTORE push button in the Toolbox. This will store the selectedinformation in the table and restore the background color of theSTORE push button.

SURFACE--provides the capability to select all faces or nodes of aspecific surface once youhave selected one face onthe surface. After selectingone face on a surface, clickon the SURFACE pushbutton in the Toolbox. PreCAST will open an input dialog box similar to the one shownhere. Move the cursor to the input line and type a toleranceangle. Click on the APPLY push button in the dialog box andPreCAST will select adjacent faces whose angles betweennormals are less than the tolerance you specified.

BOUNDARY CONDITIONS


Remarks SYMMETRY face set and PERIODIC Boundary Condition Node Setsdo not require assignments from the boundary condition database. Periodic boundary conditions are handled by creating two PERIODICsets. For a given pair, the nodes of one set must match up closely tothe nodes of the other set after undergoing a specified rotation andtranslation.

You may use the view tools, such as rotate, zoom, move, etc., tomanipulate the model in the work window pane to make it easier for youto make your selections.

You may examine and/or modify the boundary condition properties forBoundary Condition Database entries by clicking the READ/MODIFYpush button in the Boundary Condition Database display window. Thiswill display a Boundary Condition Description Display appropriate to thetype of boundary condition selected. The BOUNDARY CONDITIONS--DATABASE section of this manual explains the types of boundaryconditions and their parameters and attributes.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, BOUNDARYCONDITIONS--DATABASE

BOUNDARY CONDITIONS


BOUNDARY CONDITIONASSIGN VOLUME

Description ASSIGN VOLUME is a push button in the BOUNDARY CONDITIONmenu. It provides the capability to associate properties from theboundary condition database with specific material regions in themodel.

Method ASSIGN VOLUME is activated by clicking on it. This results in theimmediate action to display amenu which lists the types ofboundary conditions which maybe assigned. The figure shownhere illustrates this option menu.

When you select an option fromthis menu by clicking the desiredpush button, PreCAST willdisplay an appropriatecombination of table displays. The figure shown here, for HEAT,is an example of these displays. The display for each option in themenu will be similar to this one,with the difference being thecontent in the boundary conditiondatabase display table.

The top-most table will contain alist of all the material IDs in themodel and the material nameswhich have been assigned tothem. Any material ID that hasno assignment will have anasterisk “*” in the VOL ASSIGNcolumn. When you click on atable entry its background will behighlighted in red and theelements with the correspondingmaterial ID will be drawn in greenin the work window pane. Thebottom-most table will contain alist of all the Boundary Conditionsin the database which correspondto the option you selected.

The procedure for associating

BOUNDARY CONDITIONS


boundary conditions with material regions is the same for each of theoptional types of boundary conditions shown in this menu. To assign aboundary condition to a material region: 1. Select the Material by clicking the desired entry in the

Assignment Table. 2. Select a boundary condition from the database by moving the

cursor down to the window displaying the Boundary ConditionDatabase entries. If the Boundary Condition you want is notvisible in the table at first, you may scroll to the desired entry.

3. When you have located the desired boundary condition entry,click on it.

4. ASSIGN the boundary condition to the material region by clickingthe ASSIGN push button in the Assignment Table. This willplace the Boundary Condition ID# in column three of theAssignment Table.

To associate boundary conditions with other material regions, repeatsteps one through four.

You can remove any assignment by selecting the desired row in theAssignment Table and clicking the CANCEL push button in that tabledisplay.

You may click on the QUIT push button at any time to close optionmenu or the table displays.

CURRENT DENSITY--allows you to assign current densities from theboundary condition database to specific material ID numbers.

MASS SOURCE--allows you to assign mass sources from the boundarycondition database to specific material ID numbers. If a masssource changes its position over time, just choose the materialID that it starts in. It is not necessary to include all the materialIDs that it might travel through.

MOMENTUM SOURCE--allows you to assign momentum sources fromthe boundary condition database to specific material IDnumbers.

SURFACE HEAT--allows you to assign heat functions from theboundary condition database to specific material ID numbers. This applies a Heat Boundary Gondition to the free surface of afluid.

VOLUMETRIC HEAT--allows you to assign volumetric heat functionsfrom the boundary condition database to specific material IDnumbers.

BOUNDARY CONDITIONS


Remarks You may use the view tools, such as rotate, zoom, move, etc., tomanipulate the model in the work window pane to make it easier for youto make your selections.

You may examine and/or modify the boundary condition properties forBoundary Condition Database entries by clicking the READ/MODIFYpush button in the Boundary Condition Database display window. Thiswill display a Boundary Condition Description Display appropriate to thetype of boundary condition selected. The BOUNDARY CONDITIONS--DATABASE section of this manual explains the types of boundaryconditions and their parameters and attributes.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, BOUNDARYCONDITIONS--DATABASE

BOUNDARY CONDITIONS


BOUNDARYPERMEABILITY

Description PERMEABILITY is a push button in the BOUNDARY menu. It providesthe capability to account for trapped gas which escapes through themold by assigning permeabilities to specific mold material regions inthe model. Permeability is primarily intended for sand or shell molds.

Method PERMEABILITY isactivated by clicking on it. This results in theimmediate action todisplay a table which listsall of the material IDs inthe model.

When you select amaterial name from thislist, the background forthat row is highlighted inred and the elements withthat material ID areredrawn in green in thework window pane. Thisis to aid you in identifyingthe location of each material ID.

To assign a permeability to a material region: 1. Select the Material by clicking the desired entry in the

Assignment Table. 2. Move the cursor to the Edit Value input line. 3. Type the desired value and press ENTER. 4. Select the desired units of measure. The right-most column of

each entry in this display contains the units of measure. This isa rotary toggle switch. Successive clicks on this switch willcycle you through the available options. You may chose from:{m**2 | cm**2 | mm**2 | ft**2 | in**2}

You can remove any assignment by selecting the desired row in theAssignment Table and entering a value of zero in the Edit Value inputline. You may click on the QUIT push button at any time to close thisdisplay.

Remarks None.


BOUNDARY

BOUNDARY CONDITIONS


INVERSE

Description INVERSE is a push button in the BOUNDARY menu which allows youto select the HEAT boundary conditions in the model for which the FilmCoefficient, Flux, and Emissivity properties will be calculated using theinverse calculation method. These calculations will be based upon thegeometry, initial conditions, boundary conditions, and thermal history.

Method INVERSE is activated by clicking on it. This results in the immediate action todisplay a table listing the HEAT boundaryconditions in the model. The figureshown here illustrates this display.

As shown in this figure, there are threecolumns on the right side of the table. The headings are: H--Film Coefficient, Q--Flux, and E--Emissivity. Beneath theseheadings are rows of toggle switches. There is one row of switches for eachHEAT boundary condition in the table. You specify the properties foreach boundary condition which are to be calculated using the inverse

calculation method by toggling the corresponding switch to the Y or yes

position.


Remarks You may perform an inverse calculation on all H, Q, and E values, aswell as for different HEAT boundary conditions at the same time. Youmay also calculate these boundary conditions using the inverse methodin conjunction with Interface--Inverse.

Related Topics BOUNDARY CONDITIONS

BOUNDARY CONDITIONS


RADIATIONDescription RADIATION is a push button in the Main Function Banner. This

function of PreCAST enables you to describe radiation data and applythem to enclosures and moving solids. When you activate theRADIATION push button, a menu is opened which allows you to workwith the various capabilities associated with RADIATION. Selectionsfrom the menu provide access to these capabilities and will bediscussed in this section.

Method RADIATION is activated by clicking on it. The initial menu is shownhere. When you select a function fromthis menu PreCAST will displayadditional Dialog Boxes, Option Lists,Data Input Windows, or sub-menus. These graphical interface tools will guideyou through the process of specifying,changing or deleting radiation information

in the database. These may be used in your model and the analysis tobe performed.

You may leave the RADIATION function by clicking another pushbutton in the Main Function Banner.

Remarks The major capabilities of the RADIATION function of PreCAST will besummarized here. Each capability will be described in greater detail inthis manual.DATABASE

Provides the data management functions for radiationinformation. You may describe attributes for Emissivity,Temperature, and Velocity and how these factors are to beapplied in your model. DATABASE allows you to add, delete,copy, and modify entries in the radiation database.

ENCLOSUREProvides the capability to select enclosure faces, combine theminto sets, and assign emissivity, temperature, and velocity datato each set.

SOLIDProvides the capability to assign velocities to solid elements.

When you select from the RADIATION menu, ProCAST’s graphicaluser interface provides a straight forward and simple procedure forworking with the various databases used by ProCAST. This databasefacility is described elsewhere in this manual. You should read aboutthis facility before attempting to modify the radiation database.


BOUNDARY CONDITIONS


RADIATIONDATABASE

Description DATABASE is a push button in the RADIATION menu which accessesthe Radiation Database. Using ProCAST’s DATABASE FACILITY youmay create, delete, or modify radiation information in the database. This radiation information may then be used for simulation andanalysis.

Method DATABASE is activated by clicking the on it. This results in theimmediate action to display a table containing any radiation data entrieswhich may be in the database. The figure shown here illustrates such adisplay.

PreCAST allows youto Read, Add, Copy,and Delete radiationinformation from theRadiation Database. These capabilitiesare described in theDATABASEFACILITY section ofthis manual. Youshould also refer tothe TABLEMAINTENANCEsection of thismanual whichdescribes ProCAST’sgraphical interfacefor maintainingtables.

This section will discuss the requirements for adding radiationinformation to the database and how you specify individual propertiesand attributes for each entry.

To add a radiation entry to the database, click on the ADD push buttonin the Radiation Database display. This will result in the immediate

action to open a sub-menu which liststhe radiation attributes which may bedescribed. This sub-menu is shownbelow.

The characteristics, properties, andmethods for defining radiation

BOUNDARY CONDITIONS


information may vary from one attribute to another.

When you choose from this menu, PreCAST will display the appropriateinput form and options as shown below. For convenience of illustration,the example shown is the result of selecting the EMISSIVITY optionfrom the sub-menu.

PreCAST also displays an option box above the Radiation Descriptiondisplay. The content of the option box depends upon the radiationattribute you selected. The option box may contain properties oroptions which are displayed as a group of push buttons, text input lines,or a combination of these. In this case, emissivity may be designatedas a CONSTANT or as a linear function of TEMPERATURE. Therefore, there are corresponding push buttons in the option box.

If the option box includesa text input line, enterdata in a text input line byplacing the cursor in thetext box, typing thedesired data, and

pressing ENTER. In some

cases, the text input linewill be accompanied by arotary toggle switch. These toggle switchesallow you to choose thedesired value from a listof options. Successiveclicks on the toggleswitch will cycle throughthe available options.

Note that PreCAST has entered the USER name and the DATE for you. PreCAST has also entered, as a default, the KEYWORD which is thesame as the file prefix you entered when you started PreCAST. Theminimum requirement for adding a radiation entry to the database is togive it a keyword name and define its properties.

All of the radiation descriptions have two input text lines in common: KEYWORD and COMMENTS. Other properties, which may bedefined, depend upon the type of radiation attribute selected.

The syntax for the common entries are described below. Followingthese descriptions, the individual options for each available radiationattribute are discussed.

KEYWORD: Enter the name you want to give the radiation database

BOUNDARY CONDITIONS


entry. The key word must begin with an alphabetic characterand may include upper and lower case characters.

COMMENTS: This portion of the Radiation Description is a free formattext box which may be used to annotate the radiation attribute. For example, you may want to describe the sources for anyproperty data or techniques used to develop the radiationinformation or its method of application.

When you select the method for describing an attribute PreCASTdynamically displays the appropriate property names, option boxes, andinput text lines.

If you select the CONSTANT option, an input box similar to the oneshown here will be displayed. It will contain a text input line and maycontain a rotarytoggle switch for theunits of measure. Successive clicks onthis push button willtoggle through theavailable options. To enter the desired value for this property orattribute move the cursor to the text input line and type the value.

When you click on the APPLY push button or press ENTER, the data

entered will be stored, and the dialog box will be closed.

You may click on the CANCEL push button to close the dialog boxwithout saving thedata.

Selecting TIME orTEMPERATUREresults in theimmediate action todisplay an input table. This table, like thedialog box for aconstant, may containrotary toggle switchesfor the units ofmeasure. As shown inthis example forEmissivity, there aretwo toggle switcheswhich also serve asthe column sub-headings for the table.

BOUNDARY CONDITIONS


Select the desired units of measure by clicking on the column headingpush buttons. Successive clicks on these push buttons will togglethrough the available options. To enter a table value, select the first ornext available table entry, move the cursor to the text input line, type


table and move the cursor to the next available table entry. When youare satisfied with the table entries, click on the STORE push button, thedata in the table will be stored, and the dialog box will be closed.


The syntax and options available for each type of radiation attribute arediscussed below. For convenience of presentation, these are presentedin alphabetical order.

BOUNDARY CONDITIONS


EMISSIVITYIs used to enter an emissivity value as a constant or as a function oftemperature. These emissivities will be applied to enclosure faces.

Enclosure faces are required to have an emissivity value if they are toparticipate in a view factor radiation solution. The CONSTANT andTEMPERATURE values are mutually exclusive. If you STORE eitherone, its respective push button will be highlighted in blue to indicate thatdata has been entered and saved.


Function of temperature: Select the temperature units from: {C |F | K | R}

Enter the temperature values in column one andemissivity values in column two.

BOUNDARY CONDITIONS


TEMPERATUREIs used to define temperatures which will be assigned to enclosurefaces. Enclosure faces are required to have a temperature value if theyare to participate in a view factor radiation solution.

You may define the temperature as a CONSTANT value or as a linearfunction of TIME. The CONSTANT and TIME values are mutuallyexclusive. If you STORE either one, its respective push button will behighlighted in blue to indicate that data has been entered and saved.

Constant: Select the temperature units from: {C | F | R | K}


Select the temperature units from: {C | F | R | K}


BOUNDARY CONDITIONS


VELOCITYIs used to define the x, y, z direction of a velocity which may be applied

to an enclosure or to solidelements in the model. Italso allows you todescribe the magnitude ofthis velocity as a functionof time. This is used inthe radiation model whenyou have a furnace,baffles, or other partsmoving relative to thecasting. A single crystalinvestment casting is anexample.

You may enter velocity asa constant or as afunction of time. Thedefault value for anycomponent is zero. Thetime function will multiplythe magnitude of thevelocity vector.

Constant: Select the velocity units from the following: {m/sec |ft/sec | in/sec | m/min | cm/min | ft/min | in/min}


Function of time: Select the time units from: {sec | min}Select the velocity units from the following: {m/sec |ft/sec | in/sec | m/min | cm/min | ft/min | in/min}

Enter the time values in column one and velocityvalues in column two.

Remarks None.


BOUNDARY CONDITIONS


RADIATIONENCLOSURE

Description ENCLOSURE is a push button in the RADIATION menu. It providesthe capability to select enclosure faces, combine them into sets, andassign emissivity, temperature, and velocity data to each set in themodel.

Method ENCLOSURE is activated by clicking on it. This results in theimmediate action to display a table containing a list of any enclosureelement sets which have been defined in the model and the emissivity,temperature, and/orvelocity attributes whichhave been assigned, ifany. A table of theradiation attributes in thedatabase is alsodisplayed. These twotable displays areseparated by a group oftools with which you mayselect enclosure facesand create element sets.

The figure shown hereillustrates these two tabledisplays and the Toolbox.

The background of atable entry, in eithertable, will be highlightedin red when it is selected. Element sets will bedrawn in red in the workwindow pane when theirrespective set entry isselected.

BOUNDARY CONDITIONS


To assign a radiation attribute to an element set:1. Select the set by clicking on the desired entry in the Assignment

Table.2. Select a radiation attribute from the database by moving the cursor

down to the window displaying the Radiation Database entries. If the Radiation entry you want is not visible in the table at first,you may scroll to the desired entry.

3. When you have located the desired radiation attribute entry, click onit.

4. ASSIGN the attribute to the element set by clicking the ASSIGNpush button in the Toolbox. This will place the radiationattribute ID# in the appropriate column (E, T, or V) of theAssignment Table.

To associate radiation attributes with element sets, repeat steps onethrough four.

PreCAST also provides the capability to create enclosure face elementsets. The Toolbox contains the tools you use to create these sets. Each tool is represented in the Toolbox as a push button which may beactivated by clicking the left mouse button. Each of these tools will bedescribed here. For convenience of presentation, they will be describedin alphabetical order.

ADD--creates an enclosure face element set entry in the AssignmentTable. When this tool is selected, an empty row is added to theAssignment Table. An asterisk “*” will be placed in eachcolumn (E, T, V) to indicate that no data has been assigned tothat entry.

It is important to note that at this point in the process theelement set entry has been created in the assignment table. However, elements have not yet been assigned to this entryand no radiation attributes have been assigned.

Each of these radiation attributes and their respectiveproperties are discussed in the Radiation Section of thismanual.

ASSIGN--associates a radiation database entry with a specificenclosure element set. To make an assignment, follow the fourstep procedure described above.

CANCEL--allows you to close the ENCLOSURE displays.

BOUNDARY CONDITIONS


DELETE--removes all enclosure elements from the set an enclosureface element set entry from the Assignment Table. To removean element set, select the desired entry in the AssignmentTable by clicking on it. This will highlight the selected entry inred. Once the desired set entry has been highlighted, click onthe DELETE push button. This will remove the entry from thetable and disassociate any elements which were stored in thisentry. DELETE does not remove elements or nodes from themodel. To complete the deletion you must click on the STOREpush button.

DESELECT--provides the capability to untag faces in a manner similarto the selection process. To deselect faces click on theDESELECT push button. Then drag the cursor over thedesired face(s) while holding the left mouse button down. Youmay also create a drag box to enclose a portion of the model bydepressing and holding the right mouse button while draggingthe cursor to form a box around the desired portion of themodel.

SELECT--allows you to tag faces for assignment to an enclosureelement set. To select faces click on the SELECT push buttonafter clicking on the intended element set in the AssignmentTable.

To select faces, drag the cursor over the desired surfaces whileholding the left mouse button down. You may also create adrag box to enclose a portion of the model by depressing andholding the right mouse button while dragging the cursor toform a box. Once a surface has been selected, its edges willbe highlighted in red in the work window pane and the STOREpush button in the Toolbox will be highlighted with a bluebackground to indicate that some faces have been selected butnot stored.

Once you release the mouse button, you need to click onSELECT again if you wish to choose more faces.

SELECT ALL--tags all of the free enclosure faces in the problem . Once a face has been selected, its edges will be highlighted inred in the work window pane and the STORE push button in theToolbox will be highlighted with a blue background to indicatethat some faces have been selected but not stored.

Before using SELECT ALL, you should click on the enclosureset in the Assignment Table where you intend to STORE theselected surface elements.

BOUNDARY CONDITIONS


STORE--places the selected surfaces into an enclosure element set inthe Assignment Table. Once you have tagged all the faces thatyou want to be in the set, click on the STORE push button inthe Toolbox. This will store the selected information in thetable and restore the background color of the STORE pushbutton.

Remarks At a minimum, you must assign emissivity and temperature data toeach element set. If the faces in the set are moving relative to thecasting, then you need to assign a velocity as well.

You may use the view tools, such as rotate, zoom, move, etc., tomanipulate the model in the work window pane to make it easier for youto make your selections.

You may examine and/or modify the entries in the Radiation Databaseby clicking the READ/MODIFY push button in the Radiation Databasedisplay window. This will display a Radiation Description Displayappropriate to the type of radiation attribute selected. The RADIATION--DATABASE section of this manual explains the types of radiationattributes and their parameters.

You should also assign ALL enclosure elements to a set or you willreceive warning messages from DataCAST.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, RADIATION--DATABASE

BOUNDARY CONDITIONS


RADIATIONSOLID

Description SOLID is a push button in the RADIATION menu. It provides thecapability to assign velocities to solid elements in the model.

Method SOLID is activated by clicking on it. This results in the immediateaction to display a table containing a list of the material regions whichhave been defined in the model. It also displays a table of thevelocities in theRadiation Database. The figure shownhere illustrates adisplay for a modelwith three materialregions.

When you select anentry from this tableby clicking on theID#, the elements inthe model with acorresponding IDnumber will be drawnin the work windowpane in green.

To assign a velocityto a region of themodel:1. Select the region

by clicking on the desiredtable entry.

2. Select a velocityfrom thedatabase bymoving thecursor downto the windowdisplayingtheRADIATIONDATABASEentries. Ifthe velocityyou want is

BOUNDARY CONDITIONS


not visible in the table at first, you may scroll to the desiredentry.

3. When you have located the desired velocity entry, click on it.4. ASSIGN the velocity to the region by clicking the ASSIGN push

button. This will place the velocity’s database sequencenumber in the “VELOCITY” column of the Assignment Table.

To associate velocities with other regions, repeat steps one throughfour.

When you are satisfied with the assignments, click on the QUIT pushbutton in the Velocity Assignment table or select any push button in theMain Function Banner. This will store the assignments and close thedisplay.

Remarks Assigning velocities to solid elements in the model may be used, forexample, for baffles which are moving relative to a casting, where youwant to solve for the temperatures in the baffles rather than imposethem. You may also construct an entire furnace out of solid elementsrather than use enclosure elements.

Emissivities for the solid elements would be applied as a heatBOUNDARY CONDITION.

If you have two groups of solid elements which are moving relative toone another, it is best to apply the velocity to the group with the leastnumber of elements. This minimizes the size of some output files.

You may examine and/or modify the properties for Radiation Databaseentries by clicking the READ/MODIFY push button in the RadiationDatabase display window. This will display the Radiation Descriptionfor the selected table entry. Further use of this capability is explainedin the RADIATION DATABASE section of this manual.

Related Topics DATABASE FACILITY, TABLE MAINTENANCE, RADIATION--DATABASE

INITIAL CONDITIONS


INITIAL CONDITIONS

Description INITIAL COND is a push button in the Main Function Banner. Thisfunction of PreCAST enables you to assign initial temperatures to eachmaterial ID in the model or extract the initial temperatures from aprevious run of ProCAST. Additionally, the FREE SURFACE option inthe INITIAL CONDITIONS menu allows you to indicate which volumesin the mesh are initially empty in free surface fluid problems. Whenyou activate the INITIAL CONDITIONS push button, a menu is openedwhich allows you to work with the various capabilities associated withINITIAL CONDITIONS. Selections from the menu provide access tothese capabilities and will be discussed in this section.

Method INITIAL CONDITIONS is activated by clicking on it. It displays themenu shown here. When you select afunction from this menu PreCAST willdisplay additional Dialog Boxes, OptionLists, Data Input Windows, or sub-menus. These graphical interface tools will guideyou through the process of specifying,changing or deleting radiation information

in the database. These may be used in your model and the analysis tobe performed.

You may leave the INITIAL CONDITIONS function by clicking anotherpush button in the Main Function Banner.

Remarks The major capabilities of the INITIAL CONDITIONS function ofPreCAST will be summarized here. Each capability will be described ingreater detail in this manual.CONSTANT

Provides the capability to specify an initial temperature for eachmaterial ID in the model.

EXTRACTProvides the capability to pull nodal temperatures for a set ofmaterials IDs at a given time step from a previous results file. This is particularly useful in die casting or permanent moldsimulations when you want to determine the temperature in themold after several cycles. Extracted temperatures overrideinitial temperatures.

INITIAL CONDITIONS


FREE SURFACEProvides the capability to specify the material volumes whichare initially empty. This is only necessary if you are setting upa free surface fluid flow problem.

When you select from the INITIAL CONDITIONS menu, ProCAST’sgraphical user interface provides a straight forward and simpleprocedure for working with the parameters and attributes associatedwith the initial temperature conditions in the model.


INITIAL CONDITIONS


INITIAL CONDITIONSCONSTANT

Description CONSTANT is a push button in the INITIAL CONDITIONS menu. Itprovides the capability to assign temperatures to material regions in themodel.

Method CONSTANT is activated by clicking on it. This results in the immediateaction to display a table containing a list of the material regions whichhave been defined in the model. It also displays an Edit Value inputline. The figure shownhere illustrates a displayfor a model with threematerial regions.

When you select an entryfrom this table by clickingon the ID#, thebackground of that row ishighlighted in red and theelements in the modelwith a corresponding IDnumber will be drawn ingreen in the work windowpane.

To assign an initialconstant temperature to aregion of the model:1. Select the region by clicking on the desired table entry.2. Enter the temperature by moving the cursor to the Edit Value input

line. Type the desired value and press ENTER.

3. Select the temperature units by clicking on the UNITS toggle switch. This is a rotary toggle, successive clicks on it will cycle youthrough the available options. These options are {C | F | R | K}.

To assign temperatures to other regions, repeat steps one throughthree.

You close the display and move to another function of PreCAST or toanother function of INITIAL CONDITIONS by clicking the appropriateMain Function Banner or Menu push button respectively.

Remarks You must specify the initial conditions in the mold.


INITIAL CONDITIONS

INITIAL CONDITIONS


EXTRACT

Description EXTRACT is a push button in the INITIAL CONDITIONS menu. Itprovides the capability to assign nodal temperatures to material regionsin the model by loading them from a previous simulation results file atthe specific time step you designate.

Method EXTRACT is activated by clicking on it. This results in the immediateaction to display a table containing a list of the material regions whichhave been defined in the model. It also displays an Extract ParametersInput dialog box. Thefigure shown hereillustrates a displayfor a model with threematerial regions.

When you select anentry from this tableby clicking on theID#, the backgroundof that row ishighlighted in red andthe elements in themodel with acorresponding IDnumber will be drawnin green in the workwindow pane.

In this table, anymaterial which hasalready beenassigned an initialvalue will behighlighted with ablue background.

To extract initial temperatures for a region of the model:1. Select the region by clicking on the desired table entry.2. Enter the full path name of the directory where the results file can be

found by moving the cursor to the Enter Directory name input

line. Type the desired value and press ENTER. If the results

are in the current directory, you may enter a period and pressENTER.

3. Enter the prefix that was used for the results file you want to use bymoving the cursor to the Prefix input line. Type the desired

value and press ENTER. PreCAST will append t.unf to the prefix

INITIAL CONDITIONS


to make a complete file name.4. Enter the time step number that you want to use as the source of the

temperatures for this model by moving the cursor to the Enter

Step value input line. Type the desired value and press ENTER.

Note: There must be results in the file for the time step youspecify. For example, if TFREQ = 5 in the solution file youindicated, the time step you enter must be some multiple of 5.

5. When you are satisfied with the Path, Prefix, Step value entries,click on the APPLY push button in the Extract Parameters Inputdialog box. This will place the prefix and step number in theappropriate columns in the list of the materials.

To extract temperatures for other regions, repeat steps one throughfive.

Once you have applied the Path, Prefix, and Step value entries, asdiscussed in step 5 above, you may look at the values in the results fileby clicking the DISPLAY push button in the Extract Parameters Inputdialog box.


Remarks EXTRACT is particularly useful in die casting or permanent moldsimulations when you want to determine the temperature in the moldafter several cycles.

Related Topics INITIAL CONDITIONS--CONSTANT

RUN PARAMETERS


INITIAL CONDITIONSFREE SURFACE

Description FREE SURFACE is a push button in the INITIAL CONDITIONS menu. It provides the capability to specify material regions in the model whichare initially empty.

Method FREE SURFACE is activated by clicking on it. This results in theimmediate action to display a table containing a list of the materialregions which have been defined in the model. The figure shown hereillustrates a displayfor a model with threematerial regions.

When you select anentry from this tableby clicking on theID#, the backgroundof that row ishighlighted in red andthe elements in themodel with acorresponding IDnumber will be drawnin green in the workwindow pane.

Material regions in this table which are specified to be initially empty willdisplay the word YES in the EMPTY column of this table.

To specify that a material region is initially empty, toggle the EMPTYswitch in that row to the desired YES or NO position.

Repeat these two steps for each region of the model which is initiallyempty.


Remarks FREE SURFACE is only necessary when you are setting up a freesurface fluid flow problem. For flow through a filter, you should specifythat the filter is initially empty.

Related Topics

RUN PARAMETERS

RUN PARAMETERS


Description RUN PARAMETERS is a push button in the Main Function Banner. This function of PreCAST enables you to specify run parameters for thevarious types of analyses to be performed. Selections from the menuprovide access to the available sets of run parameters in ProCAST. This section will discuss these capabilities and how to use them.

Method RUN PARAMETERS is activated by clicking on it. It displays the menushown here. When you select a functionfrom this menu PreCAST will displayadditional Dialog Boxes. These graphicalinterface tools will guide you through theprocess of specifying or changingindividual run parameters.

You may leave the RUN PARAMETERSfunction by clicking another push buttonin the Main Function Banner.

Remarks The RUN PARAMETERS function ofPreCAST provides the capability to specify which ProCAST capabilitieswill be used during the simulation, how they will be used, and othergeneral parameters which will govern the simulation.

The names of most frequently changed parameters will be displayed inblack. The names of the more advanced or infrequently changedparameters will be displayed in red. Next to selected parameters is arotary toggle switch which will display the available units for thatspecific parameter. Successive clicks on these toggle switches willcycle through the available options.

To enter or change a value for a parameter, place the cursor in the

desired parameter input box, type the value, and press ENTER.

RUN PARAMETERS


Information about each parameter is available on-line. To obtaininformation about a parameter, place the cursor in the desiredparameter input box and click on the HELP push button. HELP willdisplay an information window. You close the information window byclicking the QUIT push button in the HELP window.

For a specific job, as indicated by the file prefix, PreCAST displays thedefault values for the run parameters, in the dialog box, until you makea change for that job. If you change a parameter and subsequentlyRESTART the job, PreCAST will read the prefixp.dat file and use the

parameter values which have been saved there as the defaults.


RUN PARAMETERS


RUN PARAMETERSUNITS

Description UNITS is a push button in the RUN PARAMETERS menu. It providesthe capability to specify the default units of measure to be used in theoutput files.

Method UNITS is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the unit of measuretypes. Next to each category of units is a rotary toggle switch which willdisplay the availableoptions for each of thecategories. Successiveclicks on these toggleswitches will cycle throughthe available options.

The figure shown hereillustrates the UNITSdialog box. The UNITSparameters and theavailable options for eachparameter will be presented here. For convenience in presentation,they will be presented in alphabetical order.

PUNITS--specifies the pressure units to be used in the outputs.Choose from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm| psia | Ksi | lb/ft**2}

QUNITS--specifies the heat flux units to be used in the outputs.Choose from: { W/m**2 | cal/cm**2/sec | cal/mm**2/sec |Btu/ft**2/sec | Btu/in**2/sec | cal/cm**2/min | cal/mm**2/min |Btu/ft**2/min | Btu/in**2/min}

TCUNITS--specifies the thermocouple units to be used in the outputsand is only used for inverse modeling.Choose from: {C | F | R | K}

TUNITS--specifies the temperature units to be used in the outputs.Choose from: {C | F | R | K}

VUNITS--specifies the velocity units to be used in the outputs.Choose from: {m/sec | cm/sec | mm/sec | ft/sec | in /sec | m/min| cm/min | mm/min | ft/min | in/min}

You may close this display and move to another function of PreCASTor to another function of RUN PARAMETERS by clicking theappropriate Main Function Banner or Menu push button respectively.

Remarks None.

Related Topics

RUN PARAMETERS


RUN PARAMETERSGENERAL

Description GENERAL is a push button in the RUN PARAMETERS menu. Itprovides the capability to control the time stepping algorithm and thetype of output to be produced during the simulation.

Method GENERAL is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the general parametersand, if applicable, units associated with a parameter.

The figure shown above illustrates the GENERAL dialog box. Justbelow the GENERAL dialog box is a COMMENTS input line. This boxallows you to enter your own comments about this job. The commentsyou enter will be stored in the prefixp.out file. To enter comments,

place the cursor in the input line, type your comments, and pressENTER.

The GENERAL parameters and the available options for eachparameter will be discussed here. For convenience in presentation,they will be presented in alphabetical order.

RUN PARAMETERS


AVEPROP--specifies the method to be used in calculating theproperties for each element. ProCAST will calculate theproperties at each Gauss point or you may specify that theproperties be calculated only at the element center and that thisvalue will be used as an average for the whole element. Thisaveraging reduces, somewhat, the finite element integrationtime required. This averaging does not apply to the specificheat or enthalpy calculations.

Choose from: {0 to calculate at each point, or

1 to use the average}The default is 0.

CGSQ--specifies the Conjugate Gradient Squared solver flag. Thevalues specified in this parameter may be added together. Thisallows you to “build” a customized solver approach for yoursimulation.Choose from:

{0 = Use the default iterative solver ( TDMA ),1 = Use the CGSQ solver on the U momentumequation,2 = Use the CGSQ solver on the V momentumequation,4 = Use the CGSQ solver on the W momentumequation,16 = Use the CGSQ solver on the energy equation,64 = Use the CGSQ solver on the turbulence intensityequation,128 = Use the CGSQ solver on the turbulencedissipation equation, or512 = Use the CGSQ solver on the density equation forcompressible flow}The default is 0.

CONVTOL--specifies the convergence tolerance which will be used inconjunction with the default non-symmetric iterative solver.

Enter a floating (real) value. The default is 1.0000e-04.

RUN PARAMETERS


DIAG--specifies the diagonal preconditioning flag for the symmetricsolver.Choose from:

{0 = use partial Cholesky preconditioning foreverything,8 = use diagonal preconditioning for pressure,16 = use diagonal preconditioning for energy, and16384 = use diagonal preconditioning for radiosity}The default is 16384.

DT--specifies the initial time step size. Setting DT to zero when INILEV> 0 will cause ProCAST to use the DT at step INILEV.

Enter a floating (real) value. The default is 1.0000e-03.Select the units of time from: {sec | min}

DTMAX--specifies the maximum time step size.

Enter a floating (real) value. The default is 5.0000e+00.Select the units of time from: {sec | min}

INILEV--specifies the initial time level. When an analysis is firststarted, INILEV should be equal to zero. When you areresuming an analysis, INILEV should be set to the time stepfrom which you would like to continue. Note: You must haveresults for that time step.

Enter an integer value. The default is 0.

LUFAC--specifies the preconditioning parameter for the CGSQ solver. This parameter may speed-up a “large” model(500,000+

elements, 100,000+ nodes) solution

Choose from: {0 to use diagonal preconditioning, or

1 to use partial LU factorization preconditioning}The default is 1.

NCYCLE--specifies the number of casting cycles to be simulated in acontinuous mode. This parameter is used along with TCYCLE. Both NCYCLE and TCYCLE must be set. This parameter istypically used in die casting, permanent mold problems.


RUN PARAMETERS


NEWTONR--turns on the NEWTON Raphson technique for the energyequation.

Choose from: {0 to turn off the Newton Raphson technique,

1 to turn the Newton Raphson technique on, or 2 to turn on the Newton Raphson technique and use b-splines}The default is 0.

Option 2 results in using b-splines instead of linear linesegments in the representation of the thermalproperties. It is suggested that all thermal input data besmoothed before attempting to use b-splines.


NPRFR--specifies the printout frequency. This controls the time stepinterval at which results are output to the prefixp.out file.


NRSTAR--specifies the number of allowable restarts before the entirerun is abandoned. A restart occurs when the maximum numberof corrections is reached. If too many restarts are taking place,it could indicate problems with the model setup.


NSTEP--specifies the number of time steps to take in the current runand is used in conjunction with TFINAL. ProCAST willterminate the run when it reaches this limit or the TFINALvalue, whichever occurs first.


RUN PARAMETERS


PRNLEV--specifies the level of nodal results to be printed out. Thevalues specified in this parameter may be added together. Thisallows you to collect combinations of nodal information in asingle run.Choose from:

{0 = no printout,1 = nodal velocities,8 = nodal pressures,

16 = nodal temperatures,64 = nodal turbulence intensities,128 = nodal turbulence dissipation rates,1024 = nodal displacements,8192 = surface heat fluxes, and32768 = nodal magnetic potentials}The default is 0.

SDEBUG--specifies the level of solution debugging messages to becaptured. These messages are written to the p.out file.

Choose from: {0 to capture no solution debugging messages, or

1 to obtain information concerning, solver performance,time step control, and the free surface model}The default is 1.

TCYCLE--specifies the time of casting cycle to be simulated in acontinuous mode. This parameter is used along with NCYCLE. Both NCYCLE and TCYCLE must be set.


TFINAL--specifies the simulated time at which to terminate a ProCASTanalysis. If this parameter is zero, the run will be stopped bythe NSTEP parameter. If both the NSTEP and TFINALparameters are set, the simulation will be terminated basedupon which parameter is reached first.


TMODR--specifies the time step modification factor for restarts. IfMAXCOR correction steps are taken without convergence, thetime step is multiplied by TMODR. Therefore, this numbershould be less than 1.


RUN PARAMETERS


TMODS--specifies the time step modification factor for normalstepping. If the number of correction steps is less than or equalto NCORL, the subsequent time step is multiplied by TMODS. If the number of correction steps is greater than or equal toNCORU, the subsequent time step is divided by TMODS.

Enter a floating (real) value. The default is 2.0000e+00.

USER--this parameter is used to trigger user specific routines. Theseparameters are provided as hooks into ProCAST. ContactProCAST Technical Support to discuss the applicability of thisparameter for your use.

When you are satisfied with the parameters and their values, click onthe APPLY push button. This will store the values you have entered inthe prefixp.dat file.

You may close this display without saving the parameters you enteredor changes you may have made by clicking the CANCEL push button.

Remarks Changing from the TEMA solver to the CGSQ solver may improve thesolve time in “larger” (500,000+ elements, 100,000+ nodes) models.

Related Topics

RUN PARAMETERS


RUN PARAMETERSTHERMAL

Description THERMAL is a push button in the RUN PARAMETERS menu. Itprovides the capability to specify the options used in thermal analyses.

Method THERMAL is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the thermalparameters and, if applicable, units associated with a parameter.

The figure shown above illustrates the THERMAL dialog box. TheTHERMAL parameters and the available options for each parameterwill be discussed here. For convenience in presentation, they will bepresented in alphabetical order.

CLUMP--specifies the capacitance matrix lumping factor.

Enter: {0 to use consistent matrix, or

1 to use diagonal matrix}The default is 1.

CONVT--specifies the convergence criterion for temperature. A valueof around one degree is generally appropriate. Values largerthan the mushy (liquidus--solidus) zone range are notrecommended.

Enter a floating (real) value. The default is 1.0000e+00.Select the units of temperature from: {C | F | R | K}

CRELAX--specifies the heat capacity relaxation parameter.


RUN PARAMETERS


LINSRC--specifies the source term linearization parameter formicromodels. This parameter may be used in conjunction withmicromodels that control the evolution of the solid fraction andthus the release of latent heat. The default value of zeroindicates that the heat generation will only appear in the righthand side source term. A value of one will give somecontribution to the diagonal terms of the left hand side matrix. This improves numerical stability, but does require that the LHSbe factored, which would normally happen anyway.Enter:

{0 = no linearization, or1 = for linearization of the source term}The default is 0.

MFREQ--specifies the time step interval for writing micromodel resultsto the unformatted file. This parameter can be used to reducethe size of the micro results file, which can become quite largefor problems with may nodes and time steps. Note that it isonly possible to restart a run from one of the time steps thatwas written out.


MICRO--specifies the micromodeling to be performed. The valuesspecified in this parameter may be added together. This allowsyou to use a combination of micromodeling models in a singlerun.Enter an integer value based upon the following:

{0 = no micromodeling,1 = Eutectic ductile iron,2 = Equiaxed dendrite,

4 = Stable/metastable eutectic with instantaneousnucleation,8 = Stable/metastable eutectic with continuousnucleation,16 = Eutectic gray/white iron,32 = Eutectoid ductile iron,64 = Eutectoid gray iron,128 = Peritectic transformation,256 = Delta/gamma, gamma/alpha, andgamma/cementite transformations,512 = Scheil model for primary solidification, or1024 = Solid Transformations}The default is 0.

RUN PARAMETERS


MOBILE--specifies the Mobility factor. This parameter is the criticalliquid fraction at which the free surface losses its mobility. Values between zero and one are acceptable. Piping depth canbe quite sensitive to this parameter.


POROS--specifies the porosity calculations to be performed.

Choose from: {0 for no porosity calculation,

1 to compute macro porosity, or2 to compute porosity effects associated with adissolved gas}The default is 1.

QFREQ--specifies the time step interval for writing heat flux data to theunformatted results file. This parameter can be used to reducethe size of the prefixq.unf file. Heat flux results may not be of

interest to everyone, so it may be desirable to minimize the sizeof this file.


TFREQ--specifies the time step interval for writing temperature data tothe unformatted results file. This parameter can be used toreduce the size of the prefixt.unf file, which can become quite

large for problems with many nodes and time steps. Note thatit is only possible to restart a run from one of the time steps thatwas written out.


THERMAL--specifies the thermal analysis to be performed.

Choose from: {0 for no thermal analysis. Solve flow equations alone,

1 to perform thermal analysis, using temperature as theprimary variable, or2 to perform thermal analysis, using enthalpy as theprimary variable}The default is 1.

RUN PARAMETERS


TRELAX--specifies the temperature relaxation parameter. This is usedfor computing the initial guess for the temperature field in thepredictor step. TRELAX should be greater than or equal to zeroand less than or equal to one.


When you are satisfied with the parameters values, click on the APPLYpush button. This will store the values you have entered in theprefixp.dat file.


Remarks The THERMAL parameters apply to every simulation wherein theenergy equation is being solved.

Related Topics RUN PARAMETERS

RUN PARAMETERS


RUN PARAMETERSRADIATION

Description RADIATION is a push button in the RUN PARAMETERS menu. Itprovides the capability to specify radiation parameters and tolerances tobe applied during the simulation.

Method RADIATION is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the radiationparameters and, if applicable, units associated with a parameter.

The figure shown above illustrates the RADIATION dialog box. TheRADIATION parameters and the available options for each parameterwill be discussed here. For convenience in presentation, they will bepresented in alphabetical order.

ANGTOL--specifies the angle tolerance to be used with VFLIM. Radiation faces which are grouped using VFLIM tolerance arefurther differentiated by their solid angle.


ENCLID--specifies an enclosure identification number. This parameteris used in combination with VFDISP for updating view factorsby a displacement interval. ENCLID indicates which enclosureset is to be tracked, in case all the enclosure elements are notmoving at the same rate.


EPTOL--specifies the emissive power tolerance to be used with VFLIM. Radiation faces which are grouped using VFLIM tolerance arefurther differentiated by their solid angle.


RUN PARAMETERS


RDEBUG--specifies the user debug parameter for printing detailed viewfactor information. Various combinations of these files may beobtained by adding together these numbers. For example,RDEBUG = 7 gives all three files. Note that these files can bequite large, especially the prefix.vf.

Enter an integer value based upon the following:{1 for face to face view factors after symmetrization, inthe prefix.vf file,

2 for face to group view factors after symmetrization, inthe prepfix.view file (necessary to see FACE TO

GROUP in ViewCAST), or4 for row sum errors before symmetrization, in theprefix.serr file (necessary to see ROW SUM ERRORS

in ViewCAST}The default is 0.

RFREQ--specifies the radiation update frequency. This provides amechanism for recomputing the radiosities at some time stepinterval other than one. This is particularly useful if you areperforming a filling transient along with the view factor radiationmodel. In this case, the time step size may be small due to thefiling whereas the mold temperature may not be changing veryrapidly. You can save some computational time byrecomputing the radiosities at every tenth step, for example.


VFDISP--specifies the displacement interval for updating view factorsin the radiation model if there are moving relative surfaces. This is used in conjunction with ENCLID and will be used inpreference to VFTIME if both are specified.

Enter a floating (real) value. The default is 0.0000e+00.Choose the units of length from: {m | cm | mm | ft | in}. Thedefault is m.

RUN PARAMETERS


VFLIM--specifies the view factor limit. This parameter is used toagglomerate faces in the view factor calculations. This reducesthe size of the radiosity matrix and speeds up the radiationcalculations.

VFLIM can be set to a fraction between zero and one. If oneface occupies less than this fraction of the total view space, asseen from another face, the first face is combined with someothers. A value of 0.01 is a good starting point.


VFTIME--specifies the time interval for updating view factors in theradiation model if there are moving relative surfaces.

Enter a floating (real) value. The default is 0.0000e+00.Choose the units of time from: {sec | min}. The default is sec.



Remarks The RADIATION parameters come into play when the view factorradiation model is employed.


RUN PARAMETERS


RUN PARAMETERSFLOW

Description FLOW is a push button in the RUN PARAMETERS menu. It providesthe capability to specify the flow solutions to be performed and the flowtolerances to be used during simulation.

Method FLOW is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the flow parametersand, if applicable, units associated with a parameter.

The figure shown above illustrates the FLOW dialog box. The FLOWparameters and the available options for each parameter will bediscussed here. For convenience in presentation, they will bepresented in alphabetical order.

ADVECTW--specifies the weighting of advection velocities and controlsthe degree of non-linearity of the momentum equations.

ADVECTW can take on values between zero and one. Velocities at the last time step are used as the advectingvelocities if a value of zero is used. Velocities at the currenttime step are used as the advecting velocities if a value of oneis used.

Numerical experience has shown that the accuracy of naturalcirculation flows can be enhanced by using a factor of 0.5. Formost filling analyses, a value of zero works fine and requiresmuch less computational time.


RUN PARAMETERS


COARSEC--specifies the constant coefficient for the coarseningequation.


COARSEP--specifies the power coefficient for the coarsening equation.


COMPRES--specifies whether this is an incompressible flow problem ora compressible flow problem.

Choose from: {0 to specify an incompressible flow problem, or

1 to specify a compressible flow problem}The default is 0.

CONVV--specifies the convergence criterion for velocity. The valuegiven here is a fraction of the maximum velocity calculated ateach step. Generally, .05 or 5% is appropriate.


COUPLED--specifies whether the energy and fluid solutions should becoupled or decoupled within a time step.

When the analysis is decoupled, the momentum and pressureequations are solved repeatedly until convergence. Subsequently, the energy equation is solved until convergence,assuming the flow field is fixed. With a coupled analysis, theenergy equation is solved in the same loop with momentumand pressure. Both the momentum and temperatureconvergence criteria have to be met to terminate the loop. Thismethod is more accurate, but usually takes more computationaltime.

Choose from: {0 to decouple energy and fluid solutions withing a time

step, or1 to fully couple energy and fluid solutions within a timestep}The default is 0.

RUN PARAMETERS


COURANT--specifies the courant limit on time step size. Thisparameter is only used for fluids problems. If COURANT is setto 1.0, the time step will be adjusted so that the fluid willadvance no more than one element length. This is a fairlysevere limit on time step size, but will give the most accurateresults for filling transients. Acceptable results can usually beobtained with values between 10 and 50. For compressibleflow problems, a COURANT limit of 0.5 is suggested.


EDGE--controls the algorithm for advecting the free surface front alongthe wall. Using the tangent component helps the flow to goaround corners when the mesh is relatively coarse, butsometimes causes the fluid to flow preferentially along walls.

Using the nearest free stream nodal velocity provides amechanism for detaching the flow from the wall. If flowdetachments are expected, then the nearest free stream nodalvelocity option should be used.Choose from:

{0 = use the tangent component of the nearest freestream nodal velocity, or1 = use the nearest free stream nodal velocity}The default is 0.

FFREQ--specifies the flow update frequency. This provides amechanism for re-computing the velocities at some time stepinterval other than one. This might come into play if you weresolving a conjugate heat transfer problem where the velocityfield is changing on a longer time scale than the temperatures. This option is not appropriate for free surface problems.


RUN PARAMETERS


FLOW--controls the use of fluid equations. Choose from:

{0 do not solve fluid equations,1 to solve fluid equations,3 to solve fluid equations during filling, but switch overto thermal only analysis when the LVSURF fill limit isreached and NCYCLE = 1,5 to calculate the potential flow analysis using theboundary element method,9 to solve fluid equations during filling, but switch overto thermal only analysis when the LVSURF fill limit isreached and NCYCLE > 1}The default is 0 if there are no “F” materials. If “F”materials exist, the default is 1.

FLOWDEL--specifies the delay time between the end of fill and aswitch to a thermal only, FLOW = 3 simulation. This option isused in conjunction with velocity boundary conditions withactive fill limits. The time delay buys time for the fluid tocompletely settle down in the casting before the thermal onlyphase begins.

Enter a floating (real) value. The default is 1.0000e+20.Select the units of time from: {sec | min} The default is sec.

FREESF--specifies the free surface model number to be used.

Choose from: {1 = use the momentum dominated movement of free

surface, rapid filling model,2 = use the gravity dominated movement of freesurface, slow filling model, or3 = hybrid model, switch between 1 and 2 dependingupon conditions}The default is 0.

RUN PARAMETERS


GAS--specifies whether or not to consider the trapped gas effects. Ifthe option to consider trapped gas effects is chosen, trappedgas effects will be considered even when the model contains novents, gas injection, or gas diffusion through the mold. Whenfeatures normally found in a gas problem ( vents, injection, orgas diffusion through the mold ) are present in a model, GASwill be set automatically.

Choose from: {0 to not consider trapped gas effects, or

1 to consider trapped gas effects}The default is 0.

HEAD_ON--specifies the approach to be used when calculatinggravitational term in the momentum equation for flow problemswithout free surfaces.

Choose from: {0 = calculate as rho - rho_ref, or

1 = calculate as rho * g}The default is 0.

HIVISC--specifies different solution methods for viscosity in the flowproblem.

Choose from: {0 = normal flow problem,

1= high viscous flow problem. To be used when theReynolds number is less the one. This method onlyworks for viscosity less than 104 poise. In this case, theadvection terms are neglected, symmetric solvers areemployed on the momentum equations, and largedegrees of pressure relaxation are utilized, or2 = very high viscous flow problem. To be used whenthe Reynolds number is less the one. This method isalways preferred. In this case, the advection terms areneglected and momentum effect on implicitly includedwithin a Poisson pressure equation. This option usuallyallows for much larger time steps than HIVISC = 1}The default is 0.

RUN PARAMETERS


LVSURF--provides a way to switch from the filling transient to a modewhere advection is due to buoyancy and shrinkage. LVSURFturns all inlets off. It is assumed thereafter that the free surfaceis perpendicular to the gravity vector. This allows the time stepto increase significantly. The number represents the fraction of the total casting andrigging volume which is to be filled before changing modes.


MLUMP--specifies the mass matrix lumping factor.

Choose from: {0.0 to use a consistent matrix, or

1.0 to use a diagonal matrix}The default is 1.00000e+00.

NNEWTON--specifies whether the flow is newtonian or non-newtonian.

Choose from: {0 to indicate Newtonian flow, or

1 to indicate non-newtonian flow, where viscosity is afunction of shear rate}The default is 0.

PINLET--specifies a pressure drive inflow. Setting PINLET to 1indicates that all the pressure boundary conditions are alsoinflow boundary conditions. Use of this option allows one toavoid using thin filled regions at the inlets of pressure drivenproblems. It allows for filling of metal without having an initiallayer of fluid.

Enter an integer value of 0 (off) or 1 (on). The default is 0.

PLIMIT--specifies the pressure cutoff limit. You can use this parameterto turn off an inlet velocity when the back pressure exceeds thegiven value. This is useful particularly in cases where coldshuts are occurring. Otherwise, the program will keep trying toforce more mass into the fluid region, even though there is noplace for it to go, and the pressure will continue to rise.

Enter a floating (real) value. The default is 1.00000e+20.Choose the pressure units from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia | Ksi | lb/ft**2}The default is N/m**2.

RUN PARAMETERS


PREF--specifies the pressure which is to be subtracted from anyboundary condition pressure in order to convert an absolutepressure into a gauge pressure. This parameter comes intoplay when: (1) there is trapped gas, (2) a pressure boundarycondition drives the flow, (3) there are vents, and/or (4) there isgas injected. For example, if the pressure boundary conditiondrives the flow at a gauge of 1 atmosphere, the boundarycondition is set to 2 atm. PREF should be set to 1 atm.

Enter a floating (real) value. The default is 0.00000e+00.Choose the pressure units from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia | Ksi | lb/ft**2}The default is N/m**2.

PRELAX--specifies the pressure relaxation factor. PRELAX, to have aneffect, should be greater than zero and less than one. If it isleft to the default value of one, ProCAST will automaticallycompute an appropriate relaxation factor.


SPLIT--This parameter is obsolete.

TPROF--This parameter indicates that a thermal boundary layer profileis used at the wall for the energy equation with advection. Thishas been found to reduce false diffusion errors.

Choose from: {0 = do not use boundary layer profile, or

1 = use boundary layer profile}


TSOFF--This parameter specifies the time at which to switch off theflow solution. For example, TSOFF 1 42, indicates that theflow solution will be turned off 42 seconds into the simulation. If a cyclic analysis is being performed, then the flow solutionwill be turned off 42 seconds into each cycle.

Choose from: {0 = turns this option off, or

a real value sets the time}

Enter a floating (real) value. The default is 0.00000e+00.Choose the time units from: {sec | min}. The default issec.

VFREQ--specifies the time step interval for writing velocity and

RUN PARAMETERS


pressure results to the unformatted files. This parameter canbe used to reduce the size of these results files, which canbecome quite large for problems with many nodes and timesteps. Note that it is only possible to restart a run from one ofthe time steps that was written. Only the steps that are writtencan be viewed with post-processing.


WSHEAR--specifies whether or not the wall shear formulation will beused. The wall shear formulation will convert no-slip boundaryconditions into wall traction conditions.

Choose from: {0 to indicate that wall shear formulation will not be

used, or1 to indicate wall shear formulation will be used}The default is 0.



Remarks The FLOW parameters allow you to specify the type of fluids analysisto be performed. They also allow you to make adjustments to controlsome trade-off between speed and accuracy.


RUN PARAMETERS


RUN PARAMETERSTURBULENCE

Description TURBULENCE is a push button in the RUN PARAMETERS menu. Itprovides the capability to specify turbulence parameters to be appliedduring the simulation.

Method TURBULENCE is activated by clicking on it. This results in theimmediate action to display a dialog box containing a list of theturbulence parameters.

The figure shown above illustrates the TURBULENCE dialog box. TheTURBULENCE parameters and the available options for eachparameter will be discussed here. For convenience in presentation,they will be presented in alphabetical order.

CMU--specifies the proportionality constant used in the turbulentviscosity equation. See Equation C.6.1 in Appendix C.


CONE--specifies the proportionality constant used in the production ofturbulent energy dissipation. See Equation C.5.1 in AppendixC.


CTWO--specifies the proportionality constant used in the destruction ofturbulent energy dissipation. See Equation C.5.1 in AppendixC.


KAPPA--specifies the Von Karman’s constant, usually taken as 0.4


RUN PARAMETERS


SIGMAE--specifies the diffusivity modifier used in the turbulent energydissipation transport equation. See Equation C.5.1 in AppendixC.


SIGMAK--specifies the diffusivity modifier used in the turbulent kineticenergy transport equation. See Equation C.4.1 in Appendix C.


TBRELAX--specifies the turbulence relaxation parameter.


TURB--specifies whether the turbulent flow model is turned on or off. Amodel started with TURB = 1 can be restarted at a later timewith TURB = 0. This allows laminar conditions to be consideredduring mushy or natural circulation flows.

Once TURB has been set to zero, the turbulence model can notbe restarted at a later time. Setting TURB to one for a flowproblem which has no turbulence boundary conditions assignedis okay; ProCAST will automatically define them.

Enter:{0 to turn the turbulent flow model off, or1 to turn the turbulent flow model on}The default is 0.



Remarks The default TURBULENCE parameters are used in the standard �---�

model, but they are all adjustable.


RUN PARAMETERS


RUN PARAMETERSSTRESS

Description STRESS is a push button in the RUN PARAMETERS menu. Itprovides the capability to specify stress parameters and tolerances tobe applied during the simulation.

Method STRESS is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the stress parametersand, if applicable, options associated with a parameter.

The figure shown above illustrates the STRESS dialog box. TheSTRESS parameters and the available options for each parameter willbe discussed here. For convenience in presentation, they will bepresented in alphabetical order.

CONVS--specifies the convergence criterion for the stress calculation.


SFREQ--specifies the time step interval for writing stress results to theunformatted files. This parameter can be used to reduce thesize of these files, which can become quite large for problemswith many nodes and time steps. Note that it is only possible torestart a run from one of the time steps that was written. Thisalso controls the frequency for performing stress analysis.


RUN PARAMETERS


STRESS--specifies whether the stress calculation is turned on or off.Enter:

{0 to turn the stress calculation off, or1 to turn the stress calculation on}The default is 0.



Remarks The default STRESS parameters are those normally used in moststress models, but they are all adjustable.


RUN PARAMETERS


RUN PARAMETERSELECTROMAGNETIC

Description ELECTROMAGNETIC is a push button in the RUN PARAMETERSmenu. It provides the capability to specify electromagnetic parametersto be applied during the simulation.

Method ELECTROMAGNETIC is activated by clicking on it. This results in theimmediate action to display a dialog box containing a list of theelectromagnetic parameters and, if applicable, options associated witha parameter.

The figure shown above illustrates the ELECTROMAGNETIC dialogbox. The ELECTROMAGNETIC parameters and the available optionsfor each parameter will be discussed here. For convenience inpresentation, they will be presented in alphabetical order.

CFREQ--specifies the driving frequency ( hertz ) of the current whichflows inside the induction coil.


EFREQ--specifies the time step interval for writing electromagneticresults to the unformatted files. This parameter can be used toreduce the size of these files, which can become quite large forproblems with many nodes and time steps. Note that it is onlypossible to restart a run from one of the time steps that waswritten out.


EM--specifies whether the electromagnetic calculation is turned on oroff.

Enter:{0 to turn the electromagnetic calculation off, or1 to turn the electromagnetic calculation on}The default is 0.

RUN PARAMETERS


EMITER--specifies the number of solver iterations allowed whensolving the magnetic potential equations.




Remarks To run electromagnetics EM must be set to 1 and CFREQ has to begiven a realistic value.


RUN PARAMETERS


RUN PARAMETERSINVERSE

Description INVERSE is a push button in the RUN PARAMETERS menu. Itprovides the capability to specify inverse parameters and tolerances tobe applied during the simulation.

Method INVERSE is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the inverseparameters.

The figure shown above illustrates the INVERSE dialog box. TheINVERSE parameters and the available options for each parameter willbe discussed here. For convenience in presentation, they will bepresented in alphabetical order.

CONV--specifies the convergence tolerance. The convergence will bereached when the variation, between two iterations, of eachproperty will be smaller than this value.


ITERMAX--specifies the maximum number of iterations before thecalculation is terminated. In some cases, if the tolerance is toosmall, the variation of the beta values will not be within thetolerance, although the calculation would have converged. Avalue between 15 and 30 iterations is reasonable.


SIGMA--specifies the weighting coefficient for temperature. Theweighting coefficient for temperature should be kept small inorder to have good convergence. A value of 0.1( C has provento give good results.


RUN PARAMETERS


TAU--specifies the time constant for the filtering of measurements. Inorder to remove small perturbations which might occur duringthe measurements, the curves are filtered using the timeconstant. The units of TAU are seconds.

Enter a floating (real) value. The default is 1.0000e+00

VARB--specifies the variation of each beta value during an iteration. During an iteration, the beta values will be perturbed one afterthe other in order to determine the sensitivity coefficients ofeach property. To do so, each beta value will be changed by agiven amount corresponding to the value of varb times the betavalue. Values of varb between 0.05 and 0.2 are convenientand correspond to a variation of 5 to 20% of the beta values.




Remarks A display window is displayed in which you must enter the nodenumbers or node coordinates which correspond to the location of themeasurement points. The order of this list should correspond to theorder of the measured curves in the measurement file, prefixim.dat.

The proper sequencing of these lists is mandatory because thecalculated and measured curves will be compared in the inversecalculation and should correspond to the identical location.


RUN PARAMETERS


RUN PARAMETERSCAFE

Description CAFE is a push button in the RUN PARAMETERS menu. It providesthe capability to specify parameters and tolerances to be applied to theCAFE model during thesimulation.

Editor’s Note: The CAFE capability has not yet been implemented in ProCAST.

Method CAFE is activated by clicking on it. This results in the immediate actionto display a dialog box containing a list of the CAFE parameters and, ifapplicable, units associated with a parameter.

The figure shown above illustrates the CAFE dialog box. The CAFEparameters and the available options for each parameter will bediscussed here. For convenience in presentation, they will bepresented in alphabetical order.

CELLSZ--is the length dimension for the cellular automata cells.

Enter a floating (real) value. The default is 0.0000e+00.Select the units of measure from: {m | cm | mm | ft | in}. Thedefault is m.

ISEED--is the initialization parameter for random number generation.


When you are satisfied with the parameters and their values, click onthe APPLY push button. This will store the values you have entered inthe prefixp.dat file. You may close this display without saving the

parameters you entered or changes you may have made by clicking theCANCEL push button.

Remarks None.


USING DATACAST

USING DATACAST, PAGE 4 - 1

CHAPTER 4

USING DataCAST

Description DataCAST reviews the total model, performs extensive error checking,and converts all the units into standard CGS. DataCAST also creates asummary file which describes the complete analysis model. Thissummary file provides one form of model documentation.

When DataCAST has completed its error checking, it creates the binaryfiles which will be read by ProCAST as the simulation input.

Method DataCAST runs in a either a Unix or a Microsoft Windows NT sessionwindow.

DataCAST can be started using the following command line instructionat the session window prompt or the Run Dialog Window:

datacast {prefix} [-u | -v | -d ] ENTER


DataCAST may also be started from the EXECUTE menu in the PCSscreen.

-u is an update option. This recreates the model files without re-initializing the results.

-v is a command line option which specifies verbose output in the errormessages. By default, nodes and elements are no longerprinted in error messages.

-d is a command line option which specifies that the determinant of theJacobian should be checked. This identifies bad elements.

Remarks If you start a DataCAST session without the prefix parameter shownabove, you will be given a message in the session window andprompted to enter a prefix.

The formatted file containing the description of the problem is theprefixd.dat file. This is the file which is read by DataCAST. The

complete file format and record description for this file may be found inAppendix D.

USING DATACAST


If DataCAST encounters any errors in the model, it will displayappropriate messages on the workstation screen. These errormessages are also written into the formatted file prefixd.out. When

DataCAST has completed its processing, the formatted file prefixd.out

will be available for viewing. This file contains a log of all thegeometry, material properties, and boundary/initial conditions convertedinto CGS units, and any error messages. Temperatures are in units ofdegrees Kelvin. If errors do occur, they should be corrected beforegoing on to run ProCAST.

Related Topics prefixd.dat File Format (Appendix D)

USING PROCAST

USING PROCAST, PAGE 5 - 1

CHAPTER 5

USING ProCAST

Description ProCAST performs the simulation analysis.

Method ProCAST runs in a either a Unix or a Microsoft Windows NT sessionwindow.

ProCAST can be started, on the Unix platform, using the followingcommand line instruction at the session window:

procast {prefix} [ & ] ENTER


ProCAST can be started, on the NT platform, using the followingcommand line instruction at the session window prompt or the RunDialog Window:

prosolve {prefix} [ & ] ENTER

ProCAST may also be started from the EXECUTE menu in the PCSscreen.

& is a command line option which specifies that ProCAST will be run inthe batch or background mode.

Remarks If you start ProCAST without the prefix parameter shown above, youwill be given a message in the session window and prompted to enter aprefix.

ProCAST can be run either in the foreground or in batch mode. Sincethe main number crunching occurs in ProCAST, these runs arerelatively long and batch mode is usually preferable.

When the run has finished, the results will be contained in a variety offiles. These files are described in Appendix B: ProCAST File Usage. The prefix.out file contains useful information about the run such as the

memory usage, the convergence behaviour, the iterations and cputimes taken by the solvers, etc. This can be helpful in identifyingproblems in an analysis.

You can view the formatted file prefixp.out, which can have nodal

values of temperature, pressure, velocity and heat flux. The variousunformatted results files that have the unf extension are read byPostCAST and ViewCAST for postprocessing.

There is a small utility program which can be run to report the status of

USING PROCAST


NUMBER OF STEPS = 10SIMULATED TIME = 1.023000 SECONDSTIME STEP = 0.512000 SECONDSPERCENT FILLED = 100.000000 %SOLID FRACTION = 0.000000 %CYCLE 1 IS 0.000000 % COMPLETECUP TIME = 0.070000 SECONDSSYSTEM TIME = 0.080000 SECONDSWALL CLOCK TIME = 1 SECONDSSTEP COMPLETED ON Dec 18 1996 AT 17:30:03

any ProCAST analysis which is currently running or which hascompleted its processing. This utility may be started by opening a Unixsession window and typing the following command at the sessionwindow prompt:

prostat {prefix} ENTER

ProSTAT will provide information about the simulation which includes: number of time steps completed, total simulated time, current time stepsize, percent filled, solid fraction, cycle number, elapsed CPU time, andelapsed wall clock time for the job prefix. An example of a ProSTAT

Report is shown here.

Related Topics ProCAST File Usage (Appendix B)

USING POSTCAST

USING POSTCAST, PAGE 6 - 1

CHAPTER 6

USING PostCAST

Description PostCAST provides the post-simulation capability to extract data fromthe simulation results data files and format it for further analysis. PostCAST provides the capability to graphically display temperature,velocity, pressure, fraction solid, and stress versus time results. PostCAST files may be displayed graphically using ViewCAST,PATRAN, or IDEAS.

Method PostCAST runs in a either a Unix or a Microsoft Windows NT sessionwindow.

PostCAST can be started using the following command line instructionat the session window prompt or the Run Dialog Window:

postcast {prefix} [ -f filename ] ENTER


PostCAST may also be started from the EXECUTE menu in the PCSscreen.

-f filename is a command line option for batch processing instructions.

The filename specifies the file containing the instructions. This

option currently will do just a subset of the total capabilities ofPostCAST.

Remarks If you start a PostCAST session without the prefix parameter shownabove, you will be given a in the session window and prompted to entera prefix.

When PostCAST is activated, it will display a work space with a gray(by default) background, the UES logo in the lower right-hand corner,and a Main Function Banner across the top of the work space. Youmay use the push buttons in this banner to navigate through thefunctions of PostCAST.

These functions are:OPTIONS, FORMAT, STEPS,UNITS, MATERIALS, and EXIT

Each of these functions are described in the following pages. They arepresented in the order shown above which corresponds to their left-to-right placement in the Function Banner.

USING POSTCAST


The following information can be provided by PostCAST. • Temperature results at each stored time step, • Pressure results at each stored time step, • Velocity results at each stored time step, • Turbulence quantities at each stored time step, • Heat flux results at each time stored step, • Time to reach a given temperature (Isochrons), • Temperature, fraction solid, pressure, velocity, and stress versus

time results for various nodes, • Solidification rate, cooling rate, and temperature gradient results

which can be combined into a factor indicative of microscopicfeatures,

• Niyama or LCC criteria, • R, G, L criteria, • SDAS, • Alpha case, • Feeding length at the end of solidification, and • Row sum errors from the radiation model.

Related Topics OPTIONS, FORMAT, STEPS, UNITS, MATERIALS, EXIT

OPTIONS


OPTIONS

Description OPTIONS is a push button in the Main Function Banner. This functionof PostCAST enables you to select options to be applied during the postprocessing functions. These options will influence the manipulation ofresults obtained from the ProCAST simulations and solutions. Whenyou activate the OPTIONS push button, a menu is opened which willallow you to work with specific aspects of the simulation results. Thefunctions available from this menu will be discussed in this section.

Method OPTIONS is activated by clicking on it. The initial menu is shown here. When you select a function from thismenu, PostCAST will display additionalDialog Boxes, Option Lists, Data InputWindows, or sub-menus. Thesegraphical interface tools will guide youthrough the process of specifying,changing or deleting information aboutthe options and their alternativeattributes.

You may leave the OPTIONS function byclicking another push button in the MainFunction Banner.

Remarks The OPTIONS function of PostCASTprovides the capability to select portionsof the results of the simulation for furtheranalysis, examination or processing. Forexample, this selection process allowsyou to select thermal or velocity results for every tenth node, everyother node or every 50th node for viewing and analysis. The PostCASToptions will influence the manipulation of results obtained from theProCAST simulations and solutions.

Other functions available from the PostCAST Main Function Banner,such as MATERIALS or STEPS, may affect the parameters you specifywith these OPTION parameters. For example, if you are interested inlooking at only one material, you should designate that material usingthe MATERIALS push button in the Main Function Banner beforespecifying OPTIONS. Similarly, if you are interested in examining theresults from one time step, you should designate that time step usingthe STEPS push button in the Main Function Banner before specifyingOPTIONS.

Related Topics

OPTIONS


OPTIONSX-Y PLOT

Description X-Y PLOT is a push button in the OPTIONS menu. It provides thecapability to plot the Temperature, Fraction Solid, Pressure, Velocity,and Stress and Strain versus time results of the simulation. You mayselect or specify the nodes to be displayed in the plots. Using theOPTIONS menu, X-Y PLOT also provides the capability to customize,to an extent, the appearance of the resulting plots.

Method X-Y PLOT is activated by clicking on it. This results in the immediate action todisplay a sub-menu of push buttonswhich list the types of plots for whichnodal selections may be made. Thefigure shown here illustrates this sub-menu.

When you select an option from thismenu, the background of that pushbutton is highlighted in red and anadditional sub-menu will be displayed. This sub-menu provides the capability tospecify the method by which nodes are to be selected for theTemperature, Fraction Solid, Pressure, Velocity, and Stress plotting.

Graphically, the sub-menu forspecifying the nodal values isthe same when you chooseany option excepttemperature. When youchoose TEMPERATURE, thesub-menu includes theEXTERNAL option. The example shown hereillustrates this sub-menudisplay after choosing theTemperature option. Noticethat the TEMPERATUREpush button has been highlighted.

Each of these nodal selection push button options, Interval, Nodes,Options, and External, will be discussed in this section. Forconvenience they will be presented in alphabetical order.

OPTIONS


You may close this display and move to another function of PostCASTor to another function of OPTIONS by clicking the appropriate MainFunction Banner or Menu push button respectively.

EXTERNALPostCAST allows you to read temperature - time data from othersources, such as thermocouples, to plot on the same picture as thesimulation results. The EXTERNAL push button allows you to specifythe file names containing this external data.

When you click on theEXTERNAL push button inthe sub-menu, PostCASTdisplays the file input displayas shown in the figure here.

Entering data in the table isdone by first selecting thedesired table entry. Youselect a table entry byclicking on the desired entry. If the table is empty, selectthe area in the first row. Thisis illustrated in the figureshown here.

Once a table entry is selectedthe background of that entrywill change to red and the cursor will be placed in the Enter File Nameinput box. If the entry contains data, the data will be displayed in theEnter File Name input box. You may then enter or change the filename in the input box.

You may enter up to ten different file names. If the file is not in thecurrent directory, then you need to provide the full path name and file

name. When you are satisfied with the new data, press ENTER. This

will place the value in the highlighted table entry and move the cursor tothe next available table entry.

External File contents and format--the first row of an external file shouldcontain the number of thermocouples or temperature values given ateach time. This should be followed by the thermocouple identificationnumbers which will be used to label the curves in the temperature plot. Subsequent rows in the file should have a time value and temperaturefor each thermocouple. All data is read in free format and should beseparated by a space between each value.

You may have as many thermocouple results as you can fit on one line.

OPTIONS


Up to 5000 time levels may be given in one file.

INTERVALPostCAST allows you to specify a node number interval for plotting. For example, if you wanted to see the cooling curve for every tenthnode, you would enter an interval of 10. The default is one, or everynode.

The INTERVAL option is very useful for a quick look at the thermalresults of the simulation. It can tell you if the simulation is behavingproperly or if the results are becoming erratic, which may indicate anerror in the problem’s setup.

When you click on the INTERVALpush button in the sub-menu,PostCAST displays an Edit Valueinput box as shown in the figure here.

To enter an interval value, place thecursor in the Edit Value input line, type the desired integer value, andclick on the APPLY push button.

You may close this display without specifying or changing the intervalvalue by clicking the CANCEL push button.

OPTIONS


Node SelectionCrosshairs

Node to be Selected

Node SelectionCrosshairs

The example shown here is an X-Y Plot of the temperature of a castingwhere the temperature of every 100th node was selected using theINTERVAL option.

NODESPostCAST allows you to specify node numbers for plotting. When youclick on the NODES push button inthe sub-menu, PostCAST displaysthe Nodal Values input display asshown the figure here.

Entering data in the table is done byfirst selecting the desired table entry. You select a table entry by clicking onthe desired entry. If the table isempty, select the area in the first row. This is illustrated in the figure shownhere.

If the table contains nodal values andyou want to add another value, usethe scroll bar, if necessary, to moveto the end of the table and select thefirst empty area.

Once a table entry is selected the background of that entry will changeto red and the cursor will be placed in the Edit Value Input Box. If theentry contains data, the data will be displayed in the Edit Value InputBox. You may then enter or change the node number in the Edit Value

Input Box. When you are satisfied with the new data, press ENTER.

This will place the value in the highlighted table entry and move thecursor to the next available table entry.

OPTIONS


You may also select the nodes graphically. Click on the XYZ pushbutton in the Nodal Values input display. This will display a 2D or 3Dview of the model in the Work Window Pane depending upon thegeometry of your model.

For 2D you may enter the coordinates for the node of interest to you oryou may move the cursor to a desired node in the geometry and clickon the left mouse button. When you click near or on a node in thegeometry, PostCAST will display green Node Selection Crosshairs tohelp you isolate the node and will display the node’s coordinates in theappropriate input line. This is illustrated in the figure shown here. Ifyou press and hold the left mouse button in the Work Window pane,you can “drag” the crosshairs to another position in the display. Whenyou release the mouse button the node closest to the cursor will beselected.

For 3D models, PostCAST displays a small window with three sliderbars. You can move the slider bars to control the position of theorthogonal cutting planes. Or you may enter the coordinates asdescribed above.

When you are satisfied with the selected node, click on the APPLYpush button. This will store the nodal value in the Nodal Values inputdisplay.

You may use either or both the Edit Value input line and XYZcoordinate selection techniques to enter node numbers. When you aresatisfied with all of the nodal values, click on the EXECUTE push buttonin the Nodal Values input display. This will result in PostCASTselecting the appropriate nodal data for plotting and display the plot. You may close the Nodal Values input display by clicking the CANCELpush button.

Node selection--allows you to isolate and clearly display the thermalbehavior of a few selected points in the casting. You may enter up to100 different node numbers in the Nodal Values input display.

OPTIONS


OPTIONSOPTIONS in this sub-menu provide the capability to customize, to an

extent, the appearance of the resulting plots. It also allows you toperform Cooling Curve Analyses. When you click on the OPTIONSpush button a sub-menu is displayed. The contents of this sub-menuwill be determined by the button you clicked in the X-Y menu. Thefigure shown here illustrates the options which are available when youselect TEMPERATURE. It also illustrates how PostCAST graphicallyindicates the context of the options you are specifying. When youselect an initial menu option other than TEMPERATURE, the OPTIONSsub-menu will contain only the COLOR, AUTOMATIC, and FEATUREANGLE choices. Each push button in this sub-menu affects theappearance of the plots or is used to perform the Cooling CurveAnalysis.

Each of these sub-menu push buttons will be discussed in this section.

COLOR--is a rotary toggle switch which allows you to specify therespective colors for the background and the plotted results. Bydefault, the cooling curves are drawn with various colors. However, you may find it useful to draw these plots in black ona white background or in white on a black background. Successive clicks on this toggle switch will cycle through thealternatives.

The options are: {COLOR | BLACK/WHITE | WHITE/BLACK}. The default is COLOR.

OPTIONS


AUTOMATIC/MANUAL--is a toggle switch which allows you to specifythe method to be used forscaling the Y axis in theplot. By default, thetemperature (or any otherquantity) on the Y axis isscaled automatically tothe minimum andmaximum values thatwere found among the time steps selected for display. Whenyou click on the AUTOMATIC toggle switch, a Text Input dialogbox is displayed. As shown in this figure, you may input theminimum and maximum values you want to use for scaling theY axis in the resulting plot. Successive clicks on this pushbutton will toggle between the AUTOMATIC and MANUALmethods for scaling the Y axis.

FEATURE ANGLE--determines which element edges of a mesh willappear in thegeometry plotwhileselectingXYZcoordinates. When you click on the FEATURE ANGLE push button, anangle input dialog box containing a slider bar is displayed. Asshown in this figure, you may select the degree of the featureangle by moving the slider in the horizontal scroll bar. You maymove the slider by clicking the left mouse button on either ofthe directional arrows--moving the slider one degree at a time,by clicking the left mouse button in the slide track--jumping theslider a number of degrees at a time, or by clicking on anddragging the slider--selecting the degree in a continuousmanner proportionate with the extent of the mouse movement.

The edge between two element faces will be drawn if the anglebetween the normals of the two faces is greater than or equal tothe feature angle you select. A feature angle of zero will causeall element edges to be displayed. The angle selected may bebetween zero and 180 degrees.

When you are satisfied with the Feature Angle specified, clickon the SAVE push button below the slider bar to save theselected value and close the display.

OPTIONS


DT vs TIME--is used to plot the differences between two thermalhistories as a function of time. This plot is available only fromthe TEMPERATURE X-Y PLOT option. One of the time-temperature data sets used in this comparison enters via anEXTERNAL file, as described above. The other data set istaken from the numerical results for a specified node number. You may specify the node number using the NODES capabilitydescribed above.

To select this plot, click on the DT vs TIME toggle switch in themenu. When it has been selected, the checkbox will behighlighted in burgundy. Successive clicks on this menu itemwill toggle DT vs TIME between on and off.

To view the plot, select DT vs TIME, click on the NODES pushbutton and then select the EXECUTE function a after nodalvalue has been assigned.

DT vs TIME and DT vs TEMP are mutually exclusive. If youselect DT vs TIME, DT vs TEMP will be deselected and viceversa.

DT vs TEMP--is used to plot the differences between two thermalhistories as a function of temperature. This plot is availableonly from the TEMPERATURE X-Y PLOT option. Thiscapability works like the DT vs TIME option, except theresulting plot will be as a function of temperature. You mayspecify the node number using the NODES capability describedabove.

To select this plot, click on the DT vs TEMP toggle switch in themenu. When it has been selected, the checkbox will behighlighted in burgundy. Successive clicks on this menu itemwill toggle DT vs TEMP between on and off.

To view the plot, select DT vs TEMP, click on the NODES pushbutton and then select the EXECUTE function after a nodalvalue has been assigned.

OPTIONS


1st DERIVATIVE--is a toggle switch used to indicate that you want thefirst derivative curve drawn when the cooling curve is plotted. When selected, the checkbox will be highlighted in burgundy. Successive clicks on this menu item will toggle 1stDERIVATIVE between on and off. This plot is available onlyfrom the TEMPERATURE X-Y PLOT option.

To view the plot, click on the NODES push button and thenselect the EXECUTE function after a nodal value has beenassigned or an external file has been specified. You will beasked to choose both the start and the end of solidification. You may do so by using the left mouse button to drag thecursor to the appropriate locations on the first derivative curve. You will also be asked to enter the specific heat of the metal. You may enter an average constant value of the specific heat(in c.g.s. units).

Generally, the onset of solidification is the temperaturecorresponding to maximum in the second derivative curve. The temperature value corresponding to the minimum in thefirst derivative curve (beyond the temperature corresponding tomaximum in first derivative curve) is the point wheresolidification ends. This is explained, in more detail, in theRemarks Section below under Cooling Curve Analysis.

2nd DERIVATIVE--is a toggle switch used to indicate that you want thesecond derivative curve drawn when the cooling curve isplotted. When selected, the checkbox will be highlighted inburgundy. Successive clicks on this menu item will toggle 2ndDERIVATIVE between on and off. This plot is available onlyfrom the TEMPERATURE X-Y PLOT option.

To view the plot, click on the NODES push button and thenselect the EXECUTE function after nodal values have beenassigned or external files have been specified.

GRID--is a toggle switch used to indicate whether or not you want tohave a grid displayed when the curves are plotted. Whenselected, the checkbox will be highlighted in burgundy. Successive clicks on this menu item will toggle GRID betweenon and off. This function is discussed in further detail in theRemarks Section below under Cooling Curve Analysis.

To view the plot, click on the NODES push button and thenselect the EXECUTE function after nodal values have beenassigned.

OPTIONS


SMOOTH--provides the capability to smooth an array of points whichare read from an external file. Typically the raw time-temperature data read by a thermocouple contains a lot ofnoise.. The resulting cooling curve needs to be smoothened. This push button executes a routine to smooth an array ofpoints that are in order of increasing abscissas. This plot isavailable only from the TEMPERATURE X-Y PLOT option

You activate the SMOOTHcapability by clicking theSMOOTH push button. Thiswill display an Edit Valueinput box. As shown in thisfigure, this box allows you tospecify the amount of smoothing desired.

The amount of smoothing to be performed is specified as thenumber of points over which the data needs to be smoothed. Zero gives no smoothing. Any value larger than about half ofthe total number of data points will make the output featureless. Typically, a reasonable value will be between 5 and thirty. Toenter a value, place the cursor in the Input Line, type a integervalue, and click on the APPLY push button.

This function is discussed in further detail in the RemarksSection below under Cooling Curve Analysis.

Remarks The discussion of syntax and options for Interval, Nodes, and Optionsabove may be applied to the X-Y PLOT of Temperature, Fraction Solid,Pressure, and Velocity. External, DTA, first and second derivatives andsmoothing only apply to temperature.

Cooling Curve Analysis--input is the raw time-temperature data astypically read by a thermocouple placed at a certain location ofa casting. It is read into PostCAST from an external file. Alternatively, cooling curve analysis can also be done onsimulated nodal temperature data. Usually, one thermocoupletrace is processed at a time. PostCAST’s routine for smoothingcooling curve data, which typically contains a lot of noise, usesa Fast Fourier Transform to low pass filter the data. Basedupon your input to specify the number of points over which thesmoothing is to be done, a natural cubic spline algorithm isused to interpolate a curve through these smoothened datapoints. The first and second derivative of temperature are alsodisplayed.

The temperature value corresponding to the maximum in the

OPTIONS


second derivative curve is called TEN. The time valuecorresponding to TEN is the start of the solidification. Thetemperature value corresponding to the maximum in the firstderivative curve is called MXRRES. The temperature valuecorresponding to the minimum in the first derivative curvebeyond the time value corresponding to MXRRES, is calledTES. The time value corresponding to TES gives the time forend of solidification.

After you have selected the 1st DERIVATIVE and/or 2ndDERIVATIVE options, the plots have been drawn, and youhave chosen both the start and the end of solidification on thefirst derivative curve, a cubic spline curve will be plottedbetween those two points, which is basically the derivative ofthe zero curve. Also, you will be asked to enter the specificheat of the metal. You may enter an average, constant valueof the specific heat. The area under the first derivative curveand the derivative of the zero curve between timescorresponding to TEN and TES gives the latent heat oftransformation, which is calculated by numerical integration. The latent heat value is then printed on the screen in cgs units,i.e., cal/gm.

The cooling curve analysis technique can be easily used for thedetermination of fraction of solid. By calculating the cumulativearea between the first derivative curve and the derivative of thezero curve between TEN and TES as a fraction of the total areabetween these curves, the values of the total fraction of solidevolved as a function of time are obtained. When this curve isdifferentiated with respect to time, two distinct mechanisms arenoticed. The time rate of the evolution of the fraction of solidhas two parts: one is for the initial nucleation and the other isfor bulk solidification. Usually the rate of change of fraction ofsolid curve can be assumed to be a linear function in time. Thecoefficients of this curve can easily be determined.

By taking a series of cooling curves at different locations in acasting and processing each one of them, one can evaluate thederivative of a fraction of solid curve as a function of time foreach curve. Then considering the effect of the cooling rate, ageneral time derivative of fraction of solid curve can beconstructed as a function of time and cooling rate.

In general, this cooling curve analysis technique can be used asa process control tool. It can be used to determine theoccurrence of various phases during solidification and solidstate transformation of almost all alloys. It can also be usedeffectively for control of inoculation in gray iron. The effect of

OPTIONS


inoculation on the formation of austenite can be easilydetermined using this technique because the amount ofaustenite formed can be determined. Also, carbon equivalentinformation can be predicted.

This technique can be used to obtain the latent heat ofsolidification of an unknown material, which is a good techniquefor characterization of new materials. Also, by using thistechnique, one can determine the liquidus and solidtemperatures precisely. In addition, any precipitation of phasesduring the cooling process can be easily determined.

The mathematical description of this process can be found inAppendix C, Mathematical Formulations.

Related Topics TABLE MAINTENANCE, Mathematical Formulations

OPTIONS


OPTIONSGEOMETRY

Description GEOMETRY is a push button in the OPTIONS menu. It creates anASCII file containing the nodal coordinates and element connectivitiesas they are extracted from the prefixg.unf file.

Method GEOMETRY is activated by clicking on it. This builds the ASCII file. This file can be written in either the PATRAN neutral file or the IDEASuniversal file format, depending upon the format selected from theFORMAT function in the Main Function Banner of PostCAST.

PostCAST displays an information window to indicate that the file hasbeen built successfully. The figure shown here illustrates this type ofinformation window. Notice that the name of the file built is displayedin this information window.


Remarks This geometry file represents the final configuration of the model as itgoes into ProCAST. Accordingly, it will contain any new nodes whichhave been generated and any renumbering of elements and nodes thatmay have occurred in PreCAST or DataCAST.

Related Topics

OPTIONS


OPTIONSRADIATION FACE

Description RADIATION FACE is a push button in the OPTIONS menu. It createsan ASCII file containing the nodal coordinates and elementconnectivities of only the faces that are participating in a view factorradiation model.

Method RADIATION FACE is activated by clicking on it. This results in theimmediate action to build the ASCII file. This file can be written ineither the PATRAN neutral file or the IDEAS universal file format,depending upon the format selected from the FORMAT function in theMain Function Banner of PostCAST.



Remarks This file is useful for identifying any gaps in the casting or enclosurewhich would cause large row sum errors in the view factor matrix.

Related Topics

OPTIONS


OPTIONSTEMPERATURE

Description TEMPERATURE is a push button in the OPTIONS menu. It providesthe capability to extract temperature results from the prefixt.unf file,

which is a binary file, and write them to an ASCII file. This file can bewritten in either the PATRAN neutral file or the IDEAS universal fileformat, depending upon the format selected from the FORMAT functionin the Main Function Banner of PostCAST.

Method TEMPERATURE is activated by clicking on it. This results in theimmediate action to display a sub-menu of push buttons which are themethods you may use to designate the time step levels to be includedin the output file. The figure shownhere illustrates this sub-menu.

When you select an entry from thistable by clicking the desired option,the background of that push button ishighlighted in red.

When you select the SPECIFY STEPS or SELECT STEPS optionsfrom this menu, additional input dialog tables will be opened. Thesetables provide the capability to specify time step levels to be included inthe output file.

Each of the time step selection push button options, Interval, SpecifySteps, and Select Steps, will be discussed in this section. Forconvenience they will be presented in alphabetical order.


OPTIONS


INTERVALIf you choose INTERVAL, the time step levels will be determined basedupon the values entered in the STEPS function of the Main FunctionBanner. The interval chosen must be a multiple of TFREQ, whichcontrols the frequency of output to the temperature results file.


SPECIFY STEPSSPECIFY STEPS provides thecapability to directly input thedesired time step numbers. When you click on the SPECIFYSTEPS push button in the sub-menu, PostCAST displays theinput display as shown by thefigure here.

Entering data in the table is doneby first selecting the desired tableentry. You select a table entry byclicking the desired entry. If thetable is empty, select the area inthe first row. This is illustrated inthe figure shown here.

If the table contains Step Valueinformation and you want to addanother value, use the scroll bar,if necessary, to move to the endof the table and select the firstempty area.

OPTIONS


Once a table entry is selected, the background of that entry will changeto red and the cursor will be placed in the Edit Value Input Box. If theentry contains data, the data will be displayed in the Edit Value InputBox. You may then enter or change the step value in the Edit ValueInput Box.

You may enter up to 100 different step values. When you are satisfied

with the new data, press ENTER. This will place the value in the

highlighted table entry and move the cursor to the next available tableentry.

If TFREQ has a value greater than one, the step numbers given mustbe a multiple of TFREQ. Otherwise, they are ignored.

When all the desired time steps have been entered, click on EXECUTE. This will save your selections and create the file. You will see the samemessage window that appeared for the INTERVAL option.

You may close this display without specifying or changing any time stepvalues by clicking the CANCEL push button.

SELECT STEPSSELECT STEPS providesthe capability to select timelevels from the results file. When you click on theSELECT STEPS pushbutton in the sub-menu,PostCAST displays the inputdisplay as shown the figurehere. It will contain a list ofthe time levels in the resultsfile.

You select the steps to beoutput to the ASCII file byclicking on the desired tableentries. As you selectentries in this list, they willbe highlighted with a redbackground. You maydeselect an entry by clickingon it again with the leftmouse button. Use thescroll bar, if necessary, tomove to the desired tableentry.

OPTIONS


You may deselect every entry in the list by clicking the CLEAR pushbutton.

When all the desired time steps have been selected, click onEXECUTE. This will save your selections and create the file. You willsee the same message window that appeared for the INTERVAL option.

You may close this display without specifying or changing any time stepvalues by clicking the CANCEL push button.

Remarks The ASCII file created by this function may be used as input for otheranalyses or reporting purposes outside of ProCAST.

Related Topics

OPTIONS


OPTIONSPRESSURE

Description PRESSURE is a push button in the OPTIONS menu. It provides thecapability to extract pressure results from the prefixp.unf file, which is a

binary file, and write them to an ASCII file. This file can be written ineither the PATRAN neutral file or the IDEAS universal file format,depending upon the format selected from the FORMAT function in theMain Function Banner of PostCAST.

Method PRESSURE is activated by clicking on it. This results in the immediateaction to display a sub-menu of push buttons which are the methodsyou may use to designate the time step levels to be included in theoutput file. The figure shown hereillustrates this sub-menu.

The options available in this sub-menu work in the same way as theOPTIONS--TEMPERATURE menuitem.

Please see the OPTIONS--TEMPERATURE section of this manual fora description of these menu options, their syntax, and usage.


Related Topics OPTIONS--TEMPERATURE

OPTIONS


OPTIONSVELOCITY

Description VELOCITY is a push button in the OPTIONS menu. It provides thecapability to extract velocity results from the prefix(u, v, and w).unf

files, which are binary files, and write them to an ASCII file. The threecomponents of the velocity vector at each node are output for theselected time levels. This file can be written in either the PATRANneutral file or the IDEAS universal file format, depending upon theformat selected from the FORMAT function in the Main FunctionBanner of PostCAST.

Method VELOCITY is activated by clicking on it. This results in the immediateaction to display a sub-menu of push buttons which are the methodsyou may use to designate the time step levels to be included in theoutput file. The figure shown hereillustrates this sub-menu.





OPTIONS


OPTIONSHEAT FLUX

Description HEAT FLUX is a push button in the OPTIONS menu. It provides thecapability to extract heat flux results from the prefixq.unf file, which is a

binary file, and write them to an ASCII file. This file can be written ineither the PATRAN neutral file or the IDEAS universal file format,depending upon the format selected from the FORMAT function in theMain Function Banner of PostCAST.

Method HEAT FLUX is activated by clicking on it. This results in the immediateaction to display a sub-menu of push buttons which are the methodsyou may use to designate the time step levels to be included in theoutput file. The figure shown hereillustrates this sub-menu.





OPTIONS


OPTIONSR, G, L

Description R, G, L is a push button in the OPTIONS menu. It provides thecapability to specify the method for calculating the solidification rate(R), the method for calculating the temperature gradient (G), the upperand lower temperature levels to be used in calculating the cooling rate(L), and the constants to be used in calculating the mapping factor.

Method R, G, L is activated by clicking on it. This results in the immediateaction to display an input dialog box. The figure shown here illustratesthis input dialog box.

Each of the parameters and options in this dialog box will be discussedin this section.

You may close this display by clicking the CANCEL push button.

R METHODThis push button is a toggle switch. Successive clicks on this pushbutton will toggle between method 1 and 2.

In Method 1, when each node reaches the specified temperature, apoint is located along the temperature gradient some distance away andthe time that it takes for the isotherm to reach that point is determined. R is then calculated as that distance divided by the difference in time.

In Method 2, R is calculated as the cooling rate divided by thetemperature gradient. Method 1 takes longer to compute, but it doesnot depend on the cooling rate. The results obtained by Method 2 areaffected by the temperature levels used to calculate L.

OPTIONS


G

0T0x

2

�

0T0y

2

�

0T0z

2 12

L ��

TupperTlower

tupper tlower

R METHOD options are: {1 | 2}. The default is 1.

G METHODThis push button is a rotary toggle switch. Successive clicks on thispush button will cycle through the available options. G METHOD determines if the total magnitude of the temperature gradient or onecomponent used in the calculation of the mapping factor.

G METHOD options are: {TOTAL | dT/dx | dT/dy | dT/dz}. The defaultis TOTAL.

Normally, one would choose TOTAL, in which case, the followingequation describes the magnitude of the temperature gradient.

L UPPER TEMP and L LOWER TEMPThese input lines specify the temperature levels to be used in thecalculation of the cooling rate, L. The following equation describes thecalculation of the cooling rate; where, T is temperature and t is time toreach that temperature.

For example, Tupper could be the liquidus and Tlower the solidus.

To enter these temperatures, place the cursor in the appropriate inputline and type the desired value. You may move to the next input field

by moving the cursor or by pressing ENTER.

R, G TEMPThis input line specifies the temperature to be used for the calculationof the isotherm velocity and the temperature gradient. If R, G TEMP isset to the solidus, then R will be the solidification rate. However, R canbe calculated as an isotherm velocity for any temperature.

The gradient, G, is computed at a given node when it reaches the R, GTEMP level. Therefore, G is calculated at a different time for eachnode.

To enter this temperature, place the cursor in the R, G TEMP input lineand type the desired value. You may move to the next input field by

moving the cursor or by pressing ENTER.

OPTIONS


M a R b G c L d

M

G

L

MAPPING CONSTANTSThese input lines specify the constants to be used in calculating themapping factor. The mapping factor is calculated from the formulashown here.

The a, b, c, and d are the user specified constants and correspond tothe MAPPING CONSTANTS input lines. The default values for theseconstants yield the Niyama criterion,

In the literature, L is often expressed as . If the constant is a given�T

the value of zero, the mapping factor will not be computed.

You may click on the HELP push button to obtain more informationabout various combinations of the constants which produce differentmapping factors.

When all the desired values have been entered, click on APPLY. Thiswill save your selections and create the mapping factors and mappingfactors log files. A message window will be displayed indicating whenthe files have been successfully completed.

You may close this display without specifying or changing any valuesby clicking the CANCEL push button.

Remarks R, G, L stands for solidification rate (R), temperature gradient (G), andcooling rate (L). R is the velocity of a particular isotherm. G is thegradient calculated at each node when that node reaches a giventemperature. L is the time derivative of temperature, calculated as thedifference of two temperature levels divided by the difference in time atwhich those temperatures are reached.

Choosing the R, G, L option will produce all of these results. Inaddition, they can be combined into a single product, called a mappingfactor, which can be a useful indicator of many metallurgical features. The Niyama criteria for porosity is an example.

The mapping factor log contains the temperature levels and theconstant values that were used in calculating R, G, L, and M.

By default, only a binary output file is produced for ViewCAST. If youselect PATRAN or IDEAS under the FORMAT menu, an ASCII file withthe extension "ntl" will also be created. This neutral file contains ten

OPTIONS


columns or sets of data as detailed below:

Column/Set Quantity

1 M

2 L

3 G

4 dT/dx

5 dT/dy

6 dT/dz

7 R

8 Rx

9 Ry

10 Rz

Related Topics

OPTIONS


OPTIONSFEEDING LENGTH

Description FEEDING LENGTH is a push button in the OPTIONS menu. Itprovides the capability to calculate the distance between the solidusand some user defined critical temperature which represents somefraction solid beyond which feeding is impaired. This distance is thencompared with a “critical feeding length,” which is a simple linearfunction of the hydrostatic pressure. If the feeding distance exceedsthe critical length, then porosity would be likely.

Method FEEDING LENGTH is activated by clicking on it. This results in theimmediate action to display an input dialog box. The figure shown hereillustrates this input dialog box.

Each of the parameters and options in this dialog box will be discussedin this section.

You may close this display by clicking the CANCEL push button.

A and BThese input lines allow the user to enter the constants for the criticalfeeding length equation. These critical temperatures represent somefraction solid beyond which feeding is impaired.

To enter these temperatures, place the cursor in the appropriate inputline and type the desired value. You may move to the next input field

by moving the cursor or by pressing ENTER.

OPTIONS


F Lcr A P � B

SOLIDUSThis input line is for the solidus temperature of the metal.

To enter this temperature, place the cursor in the appropriate input lineand type the desired value. You may move to the next input field by


CRITICALThis input line is for a temperature value which corresponds to afraction solid greater than zero and less than one. The critical fractionsolid at which feeding is impaired depends on the alloy, but is typicallyin the range of .6 to .8.

To enter this value, place the cursor in the appropriate input line andtype the desired value. You may move to the next input field by


When all the desired values have been entered, click on APPLY. Thiswill save your selections and close the display.

Remarks The critical feeding length is calculated from the formula shown here.

P is the hydrostatic pressure head. P is calculated automatically fromthe geometry of the casting and the metal density.

Related Topics

OPTIONS


OPTIONSISOCHRONS

Description ISOCHRONS is a push button in the OPTIONS menu. It provides thecapability to produce contours of the time that it takes to reach specifiedtemperature levels.

Method ISOCHRONS is activated by clicking on it. This results in theimmediate action to display a sub-menu which contains two optionalmethods for specifying thetemperature levels to be used. Thefigure shown here illustrates this sub-menu.

When you select either option, by clicking on the desired push button,an input dialog box will be displayed. Each option in this sub-menu willbe discussed in this section.


SEMI-AUTOProvides the capability togenerate the temperaturelevels based upon your inputof two parameters. Whenyou activate the SEMI-AUTO push button an inputdialog box is displayed. Thisis illustrated in the figurehere.

Twenty temperature levels will be generated using the START valueand incremented by the DELTA value.

START--enter the starting temperature level to be used. Place thecursor in the appropriate input line, type the desired value, and

press ENTER.

DELTA--enter the amount of temperature change you want between thegenerated temperature levels. Place the cursor in the

appropriate input line, type the desired value, and press ENTER.

OPTIONS


Click on the APPLY push button when you are satisfied with the STARTand DELTA values. You may close this display by clicking theCANCEL push button.

SPECIFY TEMPSSPECIFY TEMPS provides the capability to directly input the desiredtemperature levels. When youclick on the SPECIFY TEMPSpush button in the sub-menu,PostCAST displays the inputdisplay as shown the figurehere.

Entering data in the table isdone by first selecting thedesired table entry. You selecta table entry by clicking on thedesired entry. If the table isempty, select the area in thefirst row. This is illustrated inthe figure shown here.

If the table contains temperatureinformation and you want to addanother value, use the scrollbar, if necessary, to move to theend of the table and select thefirst empty area.

Once a table entry is selectedthe background of that entry will change to red and the cursor will beplaced in the Edit Value Input Box. If the entry contains data, the datawill be displayed in the Edit Value Input Box. You may then enter orchange the step value in the Edit Value Input Box.

You may enter up to 50 different temperature levels in this table. When

you are satisfied with the new data, press ENTER. This will place the

value in the highlighted table entry and move the cursor to the nextavailable table entry.

When you are satisfied with the temperature levels in this table, click onthe EXECUTE push button. This will close this display, calculate thetemperature levels, and build the file.

OPTIONS


With either the SEMI-AUTO or SPECIFY TEMPS method, clicking onAPPLY or EXECUTE will save your input and create the isochrons andtemperature level log files, respectively. A message window will bedisplayed indicating when the files have been successfully completed.

Remarks ISOCHRONS are particularly useful for identifying hot spots andnecking.

By default, only a binary output file is produced for ViewCAST. If youselect PATRAN or IDEAS under the FORMAT menu, an ASCII file withthe extension "ntl" will also be created.

Related Topics

OPTIONS


OPTIONSALPHA CASE

Description ALPHA CASE is a push button in the OPTIONS menu. It creates anASCII file containing information about the thickness of alpha case forthe surface nodes adjacent to the ceramic shell in Titanium alloyinvestment castings.

Method ALPHA CASE is activated by clicking on it. This results in theimmediate action to build the output file. This file can also be written ineither the PATRAN neutral file or the IDEAS universal file format,depending upon the format selected from the FORMAT function in theMain Function Banner of PostCAST.



Remarks The ALPHA CASE option is only used in Titanium castings. In Titaniumcastings there is a very brittle alpha ( � ) layer that forms on thecasting. The ALPHA CASE is used to predict the thickness of thislayer.

Surface regions of Ti alloy investment castings are usuallycontaminated with oxygen due to reactivity of the metal with theceramic shell mold during solidification and subsequent cooling fromelevated temperatures. The local increase of O2 content at the surfacepromotes the formation of oxygen-rich Ti hexagonal solid solution ( � -phase) at temperatures when bulk alloy is single phase beta ( � ). Thisalso alters the alpha/beta structure near the surface during cooling toroom temperature.

OPTIONS


Usually the thickness of this brittle layer ranges from 50 to 2000microns. This leads to deterioration of surface mechanical propertiesand it must be removed by chemical milling before use.

The thickness of the � layer needs to be predicted to determine millingtime and to determine excess thickness to be factored into the design ofas-cast dimensions. The model assumes a few typical numbers for O2

concentration at the surface, bulk region, and at the edge of the alphacase region. Also, standard values are obtained for the diffusioncoefficient and activation energy from the literature.

The ALPHA CASE option is only used in Titanium castings. In Titaniumcastings there is a very brittle oxide layer that forms on the casting. The ALPHA CASE is used to predict the thickness of the oxide layer.

Related Topics

OPTIONS


OPTIONSSDAS

Description SDAS is a push button in the OPTIONS menu. It provides thecapability of calculating the Secondary Dendrite Arm Spacing (SDAS)based upon the thermal history.

Method SDAS is activated by clicking on it. This results in the immediate actionto display an input dialog box. Thefigure shown here illustrates thisdialog box.

Each parameter in this dialog box willbe discussed in this section.

You may close this display and moveto another function of PostCAST orto another function of OPTIONS byclicking the appropriate Main Function Banner or Menu push buttonrespectively.

SDAS is calculated according to the following:

SDAS = ( M * (tend - tstart))exp

Where:tend = time to reach Tend

tstart = time to reach Tstart

TSTARTNormally taken as the liquidus. Enter the temperature value to be usedby placing the cursor in the appropriate input line, typing the desired

value, and pressing ENTER.

TENDNormally the eutectic temperature. Enter the temperature value to beused by placing the cursor in the appropriate input line, typing the

desired value, and pressing ENTER.

OPTIONS


EXPONENTProvides the capability to enter the exponent to be used in the formulashown above.

Enter the exponent by placing the cursor in the appropriate input line,

typing the desired value, and pressing ENTER.

MProvides the capability to specify the coarsening constant and is alloydependent.

Enter the coarsening constant to be used by placing the cursor in the

appropriate input line, typing the desired value, and pressing ENTER.

When you are satisfied with the values you have entered, click on theAPPLY push button. This will close this display, extract the appropriatedata, and build the ASCII file. A message window will be displayedindicating when the files have been successfully built.

Remarks In practice there is a correlation betweenthe SDAS andmechanicalproperties. Thefiner the spacing ofthe SDAS, thegreater the strength.The figure here,illustrates what SDAS is.

Related Topics

OPTIONS


OPTIONSROW SUM ERROR

Description ROW SUM ERROR is a push button in the OPTIONS menu. It createsan ASCII file containing the nodal values of row sum errors, if asimulation used the view factor radiation capabilities. These areaveraged from the row sum errors on the faces surrounding each node. Only the nodes on the radiating surfaces will have non-zero values.

Method ROW SUM ERROR is activated by clicking on it. This results in theimmediate action to build the ASCII file. This file can be written ineither the PATRAN neutral file or the IDEAS universal file format,depending upon the format selected from the FORMAT function in theMain Function Banner of PostCAST.



Remarks PostCAST looks for a file produced by ProCAST with the nameprefix.serr. This file is output from ProCAST if the value of one has

been added to RDEBUG in the prefixp.dat file.

Related Topics

OPTIONS


OPTIONSFACE TO GROUP

Description FACE TO GROUP is a push button in the OPTIONS menu. It createsan ASCII file containing the nodal values of aggregate view factors. This option is only available if a simulation used the view factorradiation capabilities. It is not necessary to create this ASCII file if youare using ViewCAST for graphical postprocessing.

Method FACE TO GROUP is activated by clicking on it. This results in theimmediate action to build the ASCII file. This file can be written ineither the PATRAN neutral file or the IDEAS universal file format,depending upon the format selected from the FORMAT function in theMain Function Banner of PostCAST.



Remarks A “face to group view factor” is the fraction of the view space from aface that is occupied by one group. A group is an assembly ofenclosure or solid faces that have the same boundary condition. Thenodal values are averaged from the surrounding face values. Only thenodes on the radiating surfaces will have non-zero values.

PostCAST will look for a file produced by ProCAST with the nameprefix.view. This file is output from ProCAST if the value of two has

been added to RDEBUG in the prefixp.dat file.

Related Topics

FORMAT


FORMAT

Description FORMAT is a push button in the Main Function Banner. This functionof PostCAST enables you to specify the type of ASCII results files to beproduced. When you activate the FORMAT push button, a menu isopened which will allow you to choose the specific output file format tobe used.

Method FORMAT is activated by clicking on it. The resulting menu is shownhere.

You select either the PATRAN neutral fileformat or the IDEAS universal file formatby clicking on the check box to the left ofeither label in the menu. When youselect a format, the background of the respective check box will behighlighted in red.

These check boxes may be toggled between on and off by successivelyclicking the check box. Additionally, these check boxes are mutuallyexclusive.

You may leave the FORMAT function by clicking another push button inthe Main Function Banner.

Remarks If you are using ViewCAST for graphical postprocessing, it is notnecessary to choose either PATRAN or IDEAS to see the results.

You do need to pick one or the other for the GEOMETRY andRADIATION FACE options.

Related Topics OPTIONS--RADIATION FACE, OPTIONS--GEOMETRY

STEPS


STEPS

Description STEPS is a push button in the Main Function Banner. This functionenables you to control the time steps used in various operations ofPostCAST. When you activate the STEPS push button, a menu isopened which will allow you to enter time step parameters. Each ofthese parameters available from this menu will be discussed in thissection.

Method STEPS is activated by clicking on it. The resulting menu input dialogbox is shown here.

You select the parameter byclicking the desiredparameter. When aparameter is selected, itsbackground will behighlighted in red.

You may leave the STEPSfunction by clicking anotherpush button in the MainFunction Banner.

STARTSpecifies the beginning time step. Enter the beginning time step byselecting START, placing the cursor in the Edit Value input line, typing

the desired value, and pressing ENTER.

ENDSpecifies the ending time step. Enter the ending time step by selectingEND, placing the cursor in the Edit Value input line, typing the desired

value, and pressing ENTER.

FREQUENCYSpecifies the frequency of the time steps to be used between theSTART and END values. Enter the frequency by selectingFREQUENCY, placing the cursor in the Edit Value input line, typing the

desired value, and pressing ENTER.

Remarks The parameters given under STEPS determine which time levels areused when plotting the temperature-time curves. They control the timelevels for which results are output in the ASCII files for temperature,pressure, velocity, and heat flux. The calculations performed for R, G,L, FEEDING LENGTH, and ISOCHRONS are all based upon thetemperature results available at the time levels chosen under STEPS.

STEPS


You can speed up these computations by using a FREQUENCY greaterthan one because not as many data points have to be examined. However, the accuracy of the results may be diminished by using toolarge a value for FREQUENCY.

The values for START, END, and FREQUENCY should be multiples ofVFREQ for pressure and velocity, and multiples of QFREQ fro heatflux. For all other cases, they should be multiples of TFREQ.

The beginning and ending time steps, and the frequency that arespecified here are used in the following functions:1. X---Y PLOT, TEMPERATURE, INTERVAL option2. X---Y PLOT, FRACTION SOLID, INTERVAL option3. X---Y PLOT, PRESSURE, INTERVAL option4. X---Y PLOT, VELOCITY, INTERVAL option5. TEMPERATURE, INTERVAL option6. PRESSURE, INTERVAL option7. VELOCITY, INTERVAL option8. HEAT FLUX, INTERVAL option9. R, G, L10. FEEDING LENGTH11. ISOCHRONS

Related Topics

UNITS


UNITS

Description UNITS is a push button in the Main Function Banner. This function ofPostCAST enables you to specify the units of measure to be used in theASCII output files.

Method UNITS is activated by clicking on it. This results in the immediateaction to display a dialog box containing a list of the unit of measuretypes. Next to each category of units is a rotary toggle switch which willdisplay the availableoptions for each ofthe categories. Successive clicks onthese toggle switcheswill cycle through theavailable options.

The figure shownhere illustrates theUNITS dialog box. The UNITSparameters and theavailable options foreach parameter willbe presented here. For convenience in presentation, they will bepresented in alphabetical order.

HEAT FLUX--specifies the heat flux units to be used in the outputs.Choose from: { W/m**2 | cal/cm**2/sec | cal/mm**2/sec |Btu/ft**2/sec | Btu/in**2/sec | cal/cm**2/min | cal/mm**2/min |Btu/ft**2/min | Btu/in**2/min}

The default is specified in QUNITS in the prefixp.dat file.

LENGTH--specifies the length units to be used in the outputs.Choose from: {m | cm | mm | ft | in}

The default is centimeters.

PRESSURE--specifies the pressure units to be used in the outputs.Choose from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm| psia | Ksi | lb/ft**2}

The default is specified in PUNITS in the prefixp.dat file.

UNITS


TEMPERATURE--specifies the temperature units to be used in theoutputs.Choose from: {C | F | R | K}

The default is specified in TUNITS in the prefixp.dat file.

VELOCITY--specifies the velocity units to be used in the outputs.Choose from: {m/sec | cm/sec | mm/sec | ft/sec | in /sec | m/min| cm/min | mm/min | ft/min | in/min}

The default is specified in VUNITS in the prefixp.dat file.

You may close this display and move to another function of PostCASTby clicking the appropriate Main Function Banner.

Remarks The length units are used in the temperature gradient and feedinglength calculations.

The temperature units are used in the TEMP-TIME PLOTS,TEMPERATURE, R, G, L, FEEDING LENGTH, and ISOCHRONfunctions.

Heat Flux, Pressure, and Velocity units affect their respective output inthe ASCII results files.

Related Topics RUN PARAMETERS--UNITS

MATERIALS


MATERIALSDescription MATERIALS is a push button in the Main Function Banner. This

function of PostCAST enables you to specify the material regions of themodel that are to be active in the calculations of the [R, G, L],FEEDING LENGTH,SDAS, X-Y PLOTS, GEOMETRY,TEMPERATURE, and ISOCHRONS functions.

Method MATERIALS is activated by clicking on it. This results in the immediateaction to display a list of all the materials in the model.

The figure shown here illustrates the MATERIALS list.

All materials that are highlightedin red will be active in thecalculations.

Materials may be excluded fromthese calculations by clicking theleft mouse button on the rowassociated with the material tobe deactivated.

You may deactivate all materialsby clicking the ALL push buttonin the Materials List display. You may reactivate a materialby clicking on the material’s entry in the list.

You may close this display and move to another function of PostCASTby clicking the appropriate Main Function Banner.

You may close this display without saving any settings you may havemade by clicking the CANCEL push button.

Remarks You can speed up the calculation process for your model bydeactivating the materials for which the [R, G, L], FEEDINGLENGTH,SDAS, X-Y PLOTS, GEOMETRY, TEMPERATURE, andISOCHRONS results are not of interest. Usually, you can turn offeverything but the casting material.

Related Topics

MATERIALS



USING VIEWCAST

USING VIEWCAST, PAGE 7 - 1

CHAPTER 7

USING ViewCASTDescription ViewCAST provides the capability to visualize the results of the

simulation. ViewCAST performs rapid contour plots of all results basedupon time step intervals which you may specify. For example,temperature contours can be plotted at every time step automatically,giving an animated effect. Also a cutting plane option allows you to seeinside the casting. You may choose from extensive menus of contoursand vectors for viewing.

Method ViewCAST runs in a either a Unix or a Microsoft Windows NT sessionwindow.

ViewCAST can be started using the following command line instructionat the session window prompt or the Run Dialog Window:

viewcast {prefix} [ -m, -G ] ENTER


ViewCAST may also be started from the EXECUTE menu in the PCSscreen.

The -m optional parameter is a switch for memory usage.The -G optional parameter is a switch for graphics statistics.

Remarks If you start a ViewCAST session without the prefix parameter shownabove, you will be given an error message in the session window andprompted to enter a prefix.

Operational procedures and standards at your installation may specifyadditional start-up requirements such as passwords, working directoryspecifications, and project or file naming conventions. Consult yourinstallation or network manager for these guidelines.

The general procedure for viewing a contour or a vector is as follows: 1. Run PostCAST to extract/calculate the desired data. For some

contours, you must use PostCAST to process the simulationresults in order to extract the data of interest to you. Forexample, in ViewCAST you can display an ISOCHRON contourwhich shows the time required to reach a given temperature.

Running PostCAST is only necessary for a subset of allvariables. These are: Isochrons, Mapping Factors, CoolingRates, Isotherm Velocity, Temperature Gradients, Alpha Case,SDAS, and Feeding Length.

2. Set the desired Steps, Parameters, and Materials for viewing. ViewCAST enables you to tailor the visualization of results to

USING VIEWCAST


best suite your analysis requirements. You can use the Stepsfunction to display a specific time step or a selected range oftime steps. The Materials function allows you to choose, basedupon material region, the results to be displayed. TheParameters function allows you to refine the presentation of thedata during viewing. For example, you may adjust the units ofmeasure, color legend, background color, and whether thevisualization will be presented in a continuous or single stepmode.

3. Activate the view. This function of ViewCAST displays the results. The graphic display window will be redrawn to show thematerial regions corresponding to your selection. Additionally,during Single Step, a set of up to four push buttons will bedisplayed in the lower right corner of the graphics display.

These push buttons allow you to; STore a copy of the image in

a file or Print a copy of the image. While the right arrow and

left arrow allow you to step forward and backward, respectivelythrough the results. These buttons are shown here along with

the dialog box which is displayed when you select the STore

option. This dialog box allows you to name the file to becreated when storing the image.The number of buttons shown is determined by ViewCASTbased upon the context and the specific results in which you

are working. For example, if you are displaying Isochrons,ViewCAST will display the first plot corresponding to the firsttemperature you specified. It will also display all four pushbuttons. This will allow you to step through all of the Isochronsgenerated in PostCAST. If you are viewing the results in the

Continuous Mode and click on PAUSE, The STore and Print

buttons will be displayed.

When ViewCAST is activated, it will display a work space, the UES logoin the lower right-hand corner, and a Main Function Banner across thetop of the work space. You may use the push buttons in this banner tonavigate through the function menus of ViewCAST.

USING VIEWCAST


These Function Banner buttons are:CONTOUR,VECTOR,STEPS,PARAMETERS,MATERIALS,VIEW,PAUSE, andEXIT

Each of these functions are described in the following pages. They arepresented in the order shown above which corresponds to their left-to-right placement in the Function Banner. This also approximates theorder in which you would ordinarily use the functions of ViewCAST.

Related Topics CONTOUR, VECTOR, STEPS, PARAMETERS, MATERIALS, VIEW,PAUSE, EXIT

CONTOUR


CONTOUR

Description CONTOUR is a push button in the Main Function Banner. This functionof ViewCAST enables you to select the category of analysis results tobe viewed. The CONTOUR push button displays a menu. The optionsin this menu represent categories of simulation results. The functionsavailable from this menu will be discussed in this section.

Method CONTOUR is activated by clicking on it. The initial menu is shownhere. When you select a function fromthis menu, ViewCAST displays sub-menus which itemize the optional classesof contours which are available.

This menu and the subsequentlydisplayed sub-menus are lists of mutuallyexclusive contour options. Only onecontour option can be active at a time. After the first selection has been made,subsequent selections will cancel thepreviously chosen contour option. When you select a contour from amenu, it will be highlighted with a blue background and the menu andsub-menu will be closed.

To display the contour, click on the VIEW push button in the mainfunction banner and then click on PICTURE.

You may deactivate all contours by clicking the NONE menu option.

You may leave the CONTOUR function by clicking another push buttonin the Main Function Banner. Each Contour Group will be discussed inthe Remarks Section immediately below.

Remarks The CONTOUR function of ViewCAST provides the capability to viewthe results of the ProCAST simulation from perspectives which willsupport your specific analytical requirements. For convenience, theseviews have been grouped as shown in the menu list above. Each ofthese groups will be discussed here.

CONTOUR


THERMAL ContoursThe figure shown here illustrates the THERMAL sub-menu and displaysthe temperature-related views which areavailable.

TEMPERATURE, FRACTION SOLID,HEAT FLUX, and SOLIDIFICATIONTIME contours will be available if athermal analysis has been run withProCAST.

ISOCHRONS, MAPPING FACTORS,COOLING RATES, TEMPERATUREGRADIENTS, ISOTHERM VELOCITY,FEEDING LENGTH, ALPHA CASE, andSDAS data is calculated by PostCASTfrom temperature results.

Setting the POROS parameter in the Thermal Run Parameters to avalue of 1 will make the MACRO POROSITY data available, andsetting the POROS parameter to a value of 2 will make the GASPOROSITY and the BUBBLE RADIUS results available.

Temperature--displays the temperatures present, at specific time steps,in the model. A temperature contour is illustrated below.

CONTOUR


Fraction Solid--displays a representation of the amount of solidificationwhich has taken place in the model at specific time steps. Afraction solid contour is illustrated here.

Heat Flux--displays a representation of the rate of heat flow, per unitarea.

Isochrons--display a plot of the time taken to get to a specifiedtemperature. The Isochrons which are available for viewingdepend upon the selection you make in theOPTIONS–ISOCHRONS function of PostCAST. The exampleshown here illustrates the elapsed time, in various portions ofthe casting, to reach 1070(C.

Mapping Factors--plots the results of the quantity calculated from thecombination of R, G, and L and is generally used as a porosityindicator.

CONTOUR


Cooling Rates--displays the cooling rates in degrees per unit of timebetween the temperatures specified in the R, G, L options ofPostCAST. In this example, the cooling rates were calculatedbetween the pour temperature of 1385 and 1000(C.

Temperature Gradients--displays the magnitude and direction of thespatial change of temperature. The gradient is composed ofthe x, y, and z components. The example shown here,illustrates the four views which ViewCAST provides. In practice

these temperature gradients can identify the degree oftemperature variation in the model.

CONTOUR


Isotherm Velocity--plots the results of the solidification rate (R) orvelocity of the isotherm value specified in the R, G, L, Option ofPostCAST.

Feeding Length--displays a plot of the distances between the solidusand a user defined temperature that represents some fractionsolid beyond which feeding is impaired. This is a porosityindicator.

Solidification Time--displays a plot of the time from the beginning to theend of solidification. In the example shown here, thesolidification time is illustrated with a cross section of thecasting.

Macro Porosity--displays the results of the macro porosity calculations.Gas Porosity--displays the results of the porosity effects associated with

a dissolved gas.Bubble Radius--displays a plot of the bubble radius as a result of the

gas porosity calculations.Alpha Case--displays the results of the calculation of Titanium oxide

formation.Secondary Dendrite Arm Spacing (SDAS)--plots the results of an SDAS

analysis.

CONTOUR


FLUID ContoursThe figure shown here illustrates the FLUID sub-menu and displays thefluid-related views which are available. The U, V, W are the velocity componentsin the X, Y, and Z directions respectively.

PRESSURE and VELOCITY contours willbe available if a fluid flow analysis hasbeen run with ProCAST.

If the fluids analysis has been run with the�---� turbulence model turned on, theTURBULENT ENERGY, TURBULENTDISSIPATION, and TURBULENT VISCOSITY contours will beavailable.

If the fluids analysis has been run with the NNEWTON parameter set to1 or 2, the NON-NEWTONIAN SHEAR RATE and VISCOSITYcontours will be available.

RADIATION ContoursThe figure shown here illustrates the RADIATION sub-menu anddisplays the radiation-related views whichare available.

Row Sum Errors–displays a contour ofthe nodal values of the row sum errors. These errors arecaused by gaps in the casting or enclosure.

Face To Group View Factors–displays the nodal values of aggregateview factors. A group is an assembly of enclosure or solidfaces that have the same boundary condition. The nodalvalues are averaged from the surrounding face values.

These contours are available if a radiation analysis was run with viewfactors specified. The RDEBUG parameter in the prefixp.dat file should

have the values of 1 and 2 added to it in order to cause ProCAST toproduce the files prefix.serr and prefix.view.

CONTOUR


STRESS ContoursThe figure shown here illustrates the STRESS sub-menu and displaysthe stress-related views which areavailable.

The state of stress at a point can becharacterized by three normalcomponents, )x , )y, )z, and three shearcomponents, )xy, )yz, )xy. )xy is the shearstress in the x direction on the y planeand so on. It is possible to find threeplanes going through this same point onwhich the shear stress is zero and there isonly a normal stress. These are called

the principal stresses , )1, )2, )3, ranked

in descending order of magnitude. Theseare the roots of the following cubicequation:

Effective Stress–is an invariant combination of the principal stressesthat gives a single value representation of the state of stress,rather than a tensor. This value is used for checking thecondition for yielding, i.e., plastic deformation. It is equivalentto the Von Mises stress, given by the formula:

Maximum Shear Stress–is also used sometimes as a criteria foryielding. It is given by the formula:

Average Normal Stress–is also known as the hydrostatic or meanstress. It is given by the formula:

Principal Stress 1--stress resolved to the direction the highestmagnitude of stress.

Principal Stress 2–stress resolved to the direction perpendicular toStress 1.

Principal Stress 3–stress resolved into or out of the plane described byStresses 1 and 2.

Sigma X--stress resolved to the x direction.

σσ σ

m ax =−1 3

2

[ ]σ σ σ σ σ σ σ= − + − + −2

2 1 22

2 32

3 12 1 2

( ) ( ) ( )/

σσ σ σ σ σ σ

m

x y z=+ +

=+ +

1 2 3

3 3

σ σ σ σ σ σ σ σ σ σ σ σ σ σ σ

σ σ σ σ σ σ σ σ σ σ σ σ

3 2 2 2 2

2 2 22 0

− + + + + + − − −

− + − − − =

( ) ( )

( )

x y z x y y z x z xy yz xz

x y z xy yz xz x yz y xz z xy

CONTOUR


Sigma Y--stress resolved to the y direction.Sigma Z–stress resolved to the z direction.Sigma XY--shear stress in the x-y plane.Sigma YZ--shear stress in the y-z plane.Sigma ZX--shear stress in the z-x plane.Effective Plastic Strain--displays a representation of normalized strain

after it goes plastic. Strain--the change in relative positions ofpoints in a medium as the result of stress-produceddeformation.

X Displacement--the amount of deformation in the x direction.Y Displacement--the amount of deformation in the y direction.Z Displacement--the amount of deformation in the z direction.

MICRO contoursA MICRO sub-menu displays the micro model-related views which areavailable. The actual sub-menu which will be displayed will dependupon the type of analysis that has been performed. The outputs fromall the different micromodels are described in the Appendix.

ELECTROMAGNETICS ContoursThe figure shown here illustrates theELECTROMAGNETICS sub-menu anddisplays the electromagnetic-relatedviews which are available.A = magnetic vector potential. This is acomplex number, with real and imaginarycomponents. This sub-menu allows youto provide each of the components of A.They include: Real Ax, Imaginary Ax,Real Ay, Imaginary Ay, Real Az,Imaginary Az, and Magnitude A.Induction Heating--is the heat generated by induced current.Eddy Current--is the electric current induced by magnetic field.Real B--magnetic flux density.Imaginary B--magnetic flux density.Lorentz Force--plots the force on a fluid due to the presence of an

electric current and magnetic field.

Related Topics Maxwell’s equations in APPENDIX C

VECTOR


VECTORDescription VECTOR is a push button in the Main Function Banner. This function

of ViewCAST enables you to select a vector plot of selected analysisresults. The VECTOR push button displays a menu of choices forproducing vector plots. The functions available from this menu will bediscussed in this section.

Method VECTOR is activated by clicking on it. The resulting menu is shownhere. The options in this menu aremutually exclusive. Only one vector plotoption can be active at a time. After thefirst selection has been made,subsequent selections will cancel thepreviously chosen option. When youselect a vector option from the menu, itwill be highlighted with a blue backgroundand the menu will be closed.

It is possible to have vector plots superimposed on contour plots. Forexample, fluid velocity vectors displayed on top of temperaturecontours can provide a great deal of information in viewing fillingtransient results. To superimpose a vector plot on a contour plot, selectthe desired contour by clicking on it in the CONTOUR menu and thenselect the desired vector from the VECTOR menu. The example belowillustrates how the Fluid Velocity Vector plot is superimposed on theFluid Velocity–Magnitude Contour.To display the plot, click on the VIEW push button in the main function

banner and then click on PICTURE.

You may deactivate all vectors by clicking the NONE menu option.

You may leave the VECTOR function by clicking another push button inthe Main Function Banner. Each menu option will be discussed in theRemarks Section immediately below.

Remarks The VECTOR function of ViewCAST provides the capability to view the

VECTOR


magnitude and orientation for selected results from a ProCASTsimulation.

FLUID VELOCITY--Fluid Velocity vectors will be available if a flowanalysis has been run with ProCAST. This plot displays themagnitude and direction of the fluid flow at specific time steps. The illustrations shown here demonstrate the capability to zoom

in on portions of the model and examine the plot at differenttime steps.

The TEMPERATURE GRADIENTS and ISOTHERM VELOCITYoptions require that the R, G, L function be executed using PostCASTto extract these vector quantities from the thermal results.

VECTOR


TEMPERATURE GRADIENTS–displays the magnitude and direction ofthe temperature change. In the example shown here, the

temperature gradient is plotted based upon the temperature of1153(C which was specified in the R, G, L Options ofPostCAST.

ISOTHERM VELOCITY---plots the vector results of the solidificationrate (R) or velocity of the isotherm value specified in the R, G,L, Option of PostCAST. In the example shown here, theisotherm velocity is plotted based upon the temperature of1153(C.

VECTOR


HEAT FLUX–displays the heat transfer into or out of the model. Thisvector plot is illustrated here.

REAL B FIELD–displays the magnetic flux density. Electromagnetic

flux is described by a complex number. This vector plots theflux associated with the real component of that number.

IMAGINARY B FIELD–displays the magnetic flux density. Electromagnetic flux is described by a complex number. Thisvector plots the flux associated with the imaginary componentof that number.

Lorentz Force–plots the force on a fluid due to the presence of anelectric current and magnetic field.

Related Topics

STEPS


STEPS

Description STEPS is a push button in the Main Function Banner. This function ofViewCAST enables you to control which time levels are used in thesequence of contour plots of temperature, pressure, velocity, and heatflux. These time steps will also be applied to fluid velocity vector plots. The STEPS push button displays an input dialog box.

Method STEPS is activated by clicking on it. The list and dialog input box,shown here, will be displayed.

To enter a value for any of the threeoptions, select the option by clicking onthe desired entry in the list. Thebackground of the selected entry will behighlighted in red. Then insert the cursorin the text input line, type the desired

value, and press ENTER. The value you

typed will be displayed in the respective entry in the list and thebackground of the next entry in the list will be highlighted in red.

You may enter or change any value in the list by repeating the select-

type-ENTER procedure described above. The entries in this list define

the following: START--specifies the first time step to be displayed for viewing. END--specifies the last time step to be displayed for viewing. FREQUENCY--specifies the number of steps between successive

displays.

You may leave the STEPS function by clicking another push button inthe Main Function Banner.

Remarks Depending upon the options you selected in the CONTOUR andVECTOR menus, the values given for START, END, and FREQUECYshould be multiples of TFREQ, VFREQ, SFREQ, MFREQ, or QFREQ.

Related Topics

MATERIALS


MATERIALS

Description MATERIALS is a push button in the Main Function Banner. Thisfunction of ViewCAST enables you to specify the material regions of themodel which are to be displayed in the graphics area.

Method MATERIALS is activated by clicking on it. This results in the immediateaction to display a list of all the materials in the model.

The figure shownhere illustrates theMATERIALS list.

Initially, all materialswill be highlightedwith a redbackground and willbe displayed.

Materials may beexcluded from thesecalculations byclicking the leftmouse button on therow associated withthe material to bedeactivated.

You may deactivate all materials by clicking the ALL push button in theMaterials List display.

You may reactivate a material by clicking on the material’s entry in thelist.

You may close this display and move to another function of ViewCASTby clicking the appropriate Main Function Banner or by clicking theQUIT push button.

Remarks As an example of how you may use this feature, consider removing themold elements from the display. This would allow you to view thecasting by itself. Selections in this window do not alter the results ordata files, they merely specify which mesh elements will be displayed inthe graphics viewing area.

Related Topics

PARAMETERS

PARAMETERS


Description PARAMETERS is a push button in the Main Function Banner. Thisfunction of ViewCAST enables you to manage the graphical outputwhich will be displayed. The options in this menu allow you to controlthe color coding used to display contours and vectors, adjust theintensity and hue of the colors used, label the output displays, anddisplay “complete” geometries which were modeled using rotational ormirror symmetry. The functions available from this menu will bediscussed in this section.

Method PARAMETERS is activated by clicking on it. The initial menu is shownhere. When you select a function fromthis menu, ViewCAST displays additionalDialog Boxes, Option Lists, Data InputWindows, or sub-menus. Thesegraphical interface tools will guide youthrough the process of specifying,changing or deleting information aboutthe options and their alternativeattributes.

Some of these switches, such asREVERSE VIDEO, toggle between onand off. Some other toggle switches,such as ALL VECTORS, are rotary toggleswitches and cycle through the availablealternatives for display attributes.

You may leave the PARAMETERSfunction by clicking another push buttonin the Main Function Banner. EachPARAMETERS menu item will be discussed immediately below.

REVERSE VIDEOREVERSE VIDEO is a toggle switch which toggles between ON andOFF. In the ON position, the background color of the contour andvector plots will be displayed in white. In the OFF position, which is thedefault, the background will be displayed in black. This may be useful,at times, for hard copy output. The toggle button is highlighted inmaroon to indicate the ON position.

PARAMETERS


AUTOMATICAUTOMATIC is a toggle switch which toggles between ON and OFF. Inthe ON position, which is the default, the color coding for displayingcontours will be determined by dividing the entire range of values of thevariable to be displayed into equal segments. Each of these calculatedsegments will be assigned to one of fifteen colors. The toggle button ishighlighted in maroon to indicate the ON position.

AUTOMATIC is toggled to the OFF position when you select andactivate either the SEMI-AUTO or MANUAL options of thePARAMETERS menu.

SEMI-AUTOSEMI-AUTO provides the capability foryou to define the color coding to be usedfor displaying contours. ViewCAST willdetermine the range of values to beassigned to a color based upon thevalues you provide. When you selectSEMI-AUTO, the list and dialog input box,shown here, will be displayed.

To enter a value, select the list item by clicking on it. The backgroundof the selected entry will be highlighted in red. Then insert the cursor in

the text input line, type the desired value, and press ENTER. The value

you typed will be displayed in the respective entry in the list and thebackground of the next entry in the list will be highlighted in red.



the following: BASE--specifies the initial value of the attribute to be displayed upon

which all display segments will be based. DELTA--specifies the size of the range of values to be included in

each of the fifteen color segments. The delta may be eitherpositive or negative, depending on whether you want the levelsto go up or down from the base value.

Each of these calculated segments will be assigned to one of fifteencolors. The toggle button is highlighted in maroon to indicate the ONposition. You may turn off the SEMI-AUTO option by activating eitherthe AUTOMATIC or MANUAL options of the PARAMETERS menu.

You may leave the SEMI-AUTO option by clicking another push buttonin the Main Function Banner or by clicking the QUIT push button.

PARAMETERS


MANUALMANUAL provides the capability for youto define the color coding to be used fordisplaying contours. When you use thisoption, you assign specific values to beassociated with a color segment. Whenyou select MANUAL, the list and dialoginput box, shown here, will be displayed.

To enter a value, select the list item byclicking on it. The background of theselected entry will be highlighted in red. Then insert the cursor in the text inputline, type the desired value, and pressENTER. The value you typed will be

displayed in the respective entry in the listand the background of the next entry inthe list will be highlighted in red.

You may enter or change any value in the

list by repeating the select-type-ENTER

procedure described above.

Each of entered value will be assigned to a color for display purposes. The toggle button is highlighted in maroon to indicate the ON position. You may turn off the MANUAL option by activating either theAUTOMATIC or SEMI-AUTO options of the PARAMETERS menu.

You may save these color assignments by clicking the STORE pushbutton and entering a file name in the Input Dialog Box which will bedisplayed.

You may leave the MANUAL option by clicking another push button inthe Main Function Banner or by clicking the DONE push button.

PARAMETERS


FREE SURFACEThis toggle switch allows you to watch the progression of the free

surface front of the fluid. This option is available only if you run a 3Dsolution. The figure shown here illustrates the free surface of a die castpart.

ENCLOSUREThis toggle switch allows you to visualize the enclosure mesh, if one ispresent. This is only used for radiation problems.

UNITSUNITS is activated by clicking on it. Thisresults in the immediate action to displaya dialog box containing a list of the unit ofmeasure types. Next to each category ofunits is a rotary toggle switch which willdisplay the available options for each ofthe categories. Successive clicks onthese toggle switches will cycle through the available options. TheUNITS parameters and the available options for each parameter will bepresented here. For convenience in presentation, they will bepresented in alphabetical order.

HEAT FLUX--specifies the heat flux units to be used in the outputs.Choose from: { W/m**2 | cal/cm**2/sec | cal/mm**2/sec |Btu/ft**2/sec | Btu/in**2/sec | cal/cm**2/min | cal/mm**2/min |Btu/ft**2/min | Btu/in**2/min}

The default is specified in QUNITS in the prefixp.dat file.

PRESSURE--specifies the pressure units to be used in the outputs.Choose from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm| psia | Ksi | lb/ft**2}

The default is specified in PUNITS in the prefixp.dat file.

STRESS--specifies the stress units to be used in the outputs.

PARAMETERS


Choose from: {N/m**2 | Pa | Kpa | Mpa | bar | dyne | cm**2 |atm | psia | Ksi | lb/ft**2}

The default is N/m**2 .

TEMPERATURE--specifies the temperature units to be used in theoutputs.Choose from: {C | F | R | K}

The default is specified in TUNITS in the prefixp.dat file.

VELOCITY--specifies the velocity units to be used in the outputs.Choose from: {m/sec | cm/sec | mm/sec | ft/sec | in /sec | m/min| cm/min | mm/min | ft/min | in/min}

The default is specified in VUNITS in the prefixp.dat file.

You may close this display and move to another function of ViewCASTby clicking the appropriate Main Function Banner.

CONTINUOUSCONTINUOUS is a toggle switch which toggles betweenCONTINUOUS and SINGLE STEP modes of displaying contours andvectors. In the CONTINUOUS mode, contour and/or vector plots whichare viewed in a time sequence will be displayed from the starting to theending time level without user intervention. This allows you to view theresults as though they were animated.

In the SINGLE STEP mode, you can step forward or backward betweentime levels. This is useful if you want to study one image at a time or toobtain a hard copy of the image. Successive clicks on this menu optionwill toggle between CONTINUOUS and SINGLE STEP.

PARAMETERS


ADJUST COLORSADJUST COLORS allows you to customize the individual colors in thespectrum. You can then save your modified spectrum in a named file. You can create as many different spectra as you like.

When you select ADJUST COLORS, the display illustrated above ispresented. The vertical color bar on the right shows the existing colorsin the spectrum.

To edit a color, click on the desired color entry in the vertical color bar. The selected color will be highlighted with a white border and that colorwill be displayed in the display box. This display box, appearinghorizontally in the window allows you to adjust the red, green, and blue(RGB) values of the color using the three slider bars. You may movethe sliders by clicking and holding the left mouse button when thecursor is over the slider knob. While you are depressing the mousebutton, you may drag the knob in either direction. You may alsoincrement and decrement these values by a value of one by clicking onthe right or left arrows (><). The color square in the horizontal windowchanges instantaneously as the RGB values change.

The current RGB value, between 0 and 255, for each color aredisplayed above the respective slider bar. When you are satisfied withthe appearance of the color, click on the SAVE push button in thehorizontal window. The modified color will be placed in the verticalcolor bar and the next color in the color bar will be loaded for editing.

PARAMETERS


You may also move directly to a particular color by clicking on it.

Once you have finished modifying the colors in the spectrum, you cansave this set by clicking the STORE push button. A Text Input window

will be displayed. In this window, enter a file name and press ENTER.

You type in any name without an extension, the extension ‘color’ will beadded to the name you give. This file will be located in the ProPATHdirectory, which is where all the other ProCAST libraries are kept. Thedefault color spectrum is kept in a file named view.color.

A previously generated spectrum can be read back in by pressing theREAD button. The same Text Input window will be displayed for you toenter the filename. Type the desired file name, without extension, and

press ENTER. Once loaded, a previously defined spectrum may be

modified and saved.

You may close the ADJUST COLORS function without saving anychanges by clicking the QUIT push button. You may also selectanother ViewCAST function from the Main Function Banner.

FEATURE ANGLEFEATURE ANGLE allows you to specify which element edges of amesh will appear in a plot. Sometimes it is desirable to see the finiteelement mesh superimposedon a plot of the results to aidin locating variousphenomena. Other times,the mesh adds visual clutter. The FEATURE ANGLE function lets youcontrol how much of the mesh you see.

When you select FEATURE ANGLE, the slider bar illustrated here isdisplayed. Values available range from 0 to 180 degrees. The edgebetween two element faces will be drawn in the plot if the anglebetween the normals of the two faces is greater than or equal to thefeature angle. A feature angle of zero will cause all element edges tobe displayed.

You may move the slider by clicking and holding the left mouse buttonwhen the cursor is over the slider knob. While you are depressing themouse button, you may drag the knob in either direction. You may alsoincrement and decrement these values by a value of one by clicking onthe right or left arrows (><). The current value of this angle is displayedabove the slider bar.

When you are satisfied with the angle, click on the APPLY push button.

You may close this display without changing the angle by clicking theCANCEL push button or by selecting another ViewCAST function from

PARAMETERS


the Main Function banner.

COLOR VECTORSCOLOR VECTORS enables you tocontrol the appearance of vector plots. When you select COLOR VECTORS asub-menu of coloring options is displayed,as shown here, is displayed.

WHITE: the vectors will be drawn inwhite if a contour option has also been selected. The length ofthe vector will indicate the relative magnitude and theorientation will show the direction.

MAGNITUDE: if vector quantities are being plotted without contours,they can be colored by their magnitude. The color spectrum onthe right of the picture will show the correspondence betweencolor and magnitude.

TEMPERATURE: if fluid velocity vectors are being plotted withoutcontours, they can be colored according to the nodaltemperatures. This type of plot provides a great deal of visualinformation.

PRESSURE: if fluid velocity vectors are being plotted withoutcontours, they can be colored according to the nodal pressures.

These menu options are mutually exclusive. The checkbox for theoption selected will be highlighted.

You may close this display by selecting another ViewCAST functionfrom the Main Funtion banner.

ALL VECTORSALL VECTORS is a toggle switch which toggles between ALLVECTORS and SURFACE VECTORS. When the ALL VECTORSoption is active, the vectors are drawn from every node in the activematerials of the problem. When the SURFACE VECTORS option isactive, vectors are only drawn from the nodes on the visible surface ofthe mesh.

PARAMETERS


ROTATIONAL SYMROTATIONAL SYM provides the capability for you to display an imageof the full geometry of an object whichyou may have modeled using therotational symmetry option. When youselect this menu option, the list anddialog input box, shown here, will bedisplayed.

ROTATIONAL SYM may be activatedby toggling the first push button in thelist to the ON position. The backgroundof the ROTATIONAL SYM menu itemwill be highlighted in blue as areminder.






the following: SECTORS--you enter the number of times the piece is repeated

around the axis of symmetry, counting the original piece as 1. DELETED SECTORS--allows you to obtain a view with a pie-shaped

cutout by entering some number greater than 0. This numbershould be less than that given for SECTORS.

X0, Y0, Z0, X1, Y1, Z1--specify the coordinates for two points thatdefine an axis of symmetry.

You may leave the ROTATIONAL SYM option by clicking another pushbutton in the Main Function Banner.

PARAMETERS


MIRROR SYM 1 and 2MIRROR SYM provides the capability for you to display an image of thefull geometry of an object which mayhave one or two planes of mirrorsymmetry. Both MIRROR SYM 1 andMIRROR SYM 2 operate in the sameway. When you select either of thesemenu options, the list and dialog inputbox, shown here, will be displayed.

MIRROR SYM may be activated bytoggling the first push button in the list tothe ON position. The background of anactive MIRROR SYM menu item will behighlighted in blue as a reminder.






the X, Y, and Z coordinates for three points that define a plane ofsymmetry.

You may leave the MIRROR SYM option by clicking another pushbutton in the Main Function Banner.

DISPLACEMENT MAG.DISPLACEMENT MAG. provides thecapability for you to control themagnification factor for deformations tothe mesh in stress analysis problems. This option is only available for stress analysis problems.

When you select this menu option a dialog input box, as illustratedhere, will be displayed.

To enter a value, insert the cursor in the text input line, type the desired

value, and press ENTER. The default value is 20.Set this value to zero

if you do not wish to see the mesh deform with time.

You may leave the DISPLACEMENT MAG. option by clicking anotherpush button in the Main Function Banner.

PARAMETERS


PARTICLESPARTICLES provides the capability foryou to inject a single particle into a fluidstream. This “tracer bullet” allows you toobserve the path of the particle over time. When you select this menu option, the listand dialog input box, shown here, will bedisplayed.

PARTICLES may be activated by togglingthe first push button in the list to the ONposition. The background of thePARTICLES menu item will behighlighted in blue when it is active.






the following: RADIUS--specifies the radius of the particle. DENSITY--specifies the density of the particle. DRAG COEF--specifies the drag coefficient the particle will exhibit. START TIME--specifies the time at which the particle will be injected

into the fluid stream. INIT {X, Y, Z} VEL--specifies the initial velocity of the particle in each

coordinate direction. NODE--specifies the node number where the particle is to be injected.

You may leave the PARTICLES option by clicking another push buttonin the Main Function Banner.

PARAMETERS


CUT-OFF

CUT-OFF provides the capability for you to specify a value which willbe used as the threshold for the values to be displayed. You maydesignate that only values above this threshold will be displayed. Conversely, you may designate that only values below this thresholdwill be displayed. For example, the figure shown here was generatedafter the criterion value was set to display only values above .6. Thefigure shows the fraction solid which was above .6 at the time step thisimage was captured.

When you select the CUT-OFF menuoption, the list and dialog input box,shown here, will be displayed.

To enter a value, insert the cursor in thetext input line, type the desired value, and

press ENTER. The value you entered will

be displayed in the VALUE line. You must indicate whether valuesabove or below this value are to be displayed. This is done by clickingthe rotary toggle switch which is directly above the VALUE line. Successive clicks on this switch will result in choosing, ABOVE,BELOW, or OFF. The default is OFF. If this option is set to ABOVE orBELOW, the background of the CRITERION menu item will behighlighted in blue.

You may leave the CRITERION option by clicking another push buttonin the Main Function Banner.

PARAMETERS


TITLESTITLES provides the capability to place up to ten titles on contour andvector plots. When you select TITLES, the window shown below isdisplayed.

For each title, you need to give X and Y screen coordinates and the textof the title to be displayed. This information is placed in the threecolumns of the input window respectively. The location for the title ismeasured in pixels from the top left corner of the graphics area to thelower left corner of the text string.

You may type these coordinates manually or you can click on the X--Ypush button and use the mouse to set the location with a click of the leftmouse button.

To enter a value in the table insert the cursor in the desired input boxand type the desired value. You may enter or change any value in thelist by highlighting and retyping the entry. You may clear a table entryby selecting the text to be deleted and pressing Delete on the keyboard. You may clear the entire table by pressing the CLEAR push button. Once you are satisfied with all the entries, press APPLY.

Remarks The PARAMETERS function of ViewCAST provides the capability totailor the view of results obtained from ProCAST. It is important to notethat these parameters do not change the geometry, simulationdescription, or any of the results data. These parameters do affect whatyou will see and how it will be displayed when you activate the VIEWcomponent of ViewCAST.

Related Topics

VIEW


VIEWDescription VIEW is a push button in the Main Function Banner. This function of

ViewCAST displays contour and vector plots. The options in this menuenable you to manipulate the graphical output which is displayed inorder to facilitate your analysis.

The functions available from this menu will be discussed in this section.

Method VIEW is activated by clicking on it. When VIEW is activated, thegeometry will be displayed in the graphicsdisplay window and the menu, shownhere, will be displayed on the right side ofthe window.

The ROTATE, ZOOM, CENTER, DRAG,HIDDEN, and RESTORE capabilities aredescribed in the VIEWING TOOLSsection of this manual and will not berepeated here.

When you select a function from thismenu, depending upon the specificoption, ViewCAST may display additionaldialog boxes, option lists, data inputwindows, or sub-menus. These graphicalinterface tools will guide you through theuse of the selected option.

You may leave the VIEW function byclicking another push button in the Main Function Banner. Each of theVIEW menu items which are not described in the VIEWING TOOLSsection of this manual will be discussed immediately below.

PICTUREThis menu option begins the contour and/or vector plotting process. The plot will be displayed based upon the contour or vector you havechosen and the parameters you set. Plotting will begin at the time stepyou specified and will be redrawn at the interval you specified in theSTEPS menu of ViewCAST. The figures in this section of the manualare examples of the plots which are displayed as a result of selectingthe PICTURE menu option.

Once you have activated the picture function, you may click on thePAUSE push button in the Main Function Banner to stop the plottingprocess.

XYZ PLANES

VIEW


This tool allows you to designate specific X, Y, and Z planes in themodel for viewing. Viewing these cross-sectional planes is athree step process: 1. Defining the

planes: When youselect theXYZ PLANES option from the VIEW menu an input box will beopened, as shown here. You define the plane(s) of interest bymoving the slider buttons in the input box. As you move aslider button, ViewCAST will display a reference outline in themodel. This allows you to position the plane in the area ofinterest. You may set a single plane or multiple planes in anyor all of the X, Y, or Z axes. ViewCAST indicates that a planehas been defined by placing a small arrow head above theslider bar for the appropriate axis. As shown in the figureabove, four planes have been defined along the X axis, and twoplanes have been defined along the Y and Z axes.

2. Activating the plane(s) to be shown: You may activate the planesalong each or all of the axes for viewing by selecting the X, Y,or Z push buttons which are shown on the left-side of the inputbox. When you select these push buttons, the background willchange to red., and

3. Viewing the PICTURE: After a plane has been defined and thedesired axis has been activated, click on the PICTURE pushbutton in the VIEW menu to display the desired cross-section.

XYZ PLANE settings may be storedfor future use by clicking the STOREpush button in the input box. This willopen an input box as shown here. Enter the file name to be given to thisset of cross sections and click on theAPPLY push button.

Once you have saved a cross-section definition, you may READ it forsubsequent viewing and analysis. When you click on the READ pushbutton as shown in the figure above, an input box will open for you toenter the name of the cross-sectional definition to be read.

The CLEAR push button in the input dialog box shown above, will clearall planes which may have been specified and resets the X, Y, and Zpush buttons to the off position.

VIEW


The figure shown here illustrates that four cross-sections have been

designated and subsequently displayed when the PICTURE menuoption of ViewCAST was selected.

ANYPLANE PLANEThis tool allows you to define cross-sectional planes by selecting threepoints in the model. Viewing thesecross-sectional planes is a three stepprocess: 1. Defining the planes: When you

select the ANYPLANE optionfrom the VIEW menu aninput box will be opened, asshown here. You define aplane by moving the cursor toeach of three points in themodel which define the planeof interest. Clicking the leftmouse button will select apoint in the model andhighlight this point with asmall + sign. When threepoints have been designated,an outline of the definedplane will be highlighted in the model. This is illustrated in thefigure below.

You may define more than one plane by clicking the NEW push buttonin the input box and selecting three points in the model.

VIEW


2. Activating the plane to be shown: You may activate a definedcross-section for viewing by selecting the desired planedefinition in the input box and clicking the OFF/ON toggleswitch in the input box. Once you have selected an entry in thislist, it will be highlighted with a red background. Note: It maybe easier for you to select specific nodes by clicking theHIDDEN menu item in the VIEW menu.

3. Viewing the PICTURE: After a plane has been defined andactivated, click on the PICTURE push button in the VIEW menuto display the desired cross-section.

ANYPLANE settings may be stored for future use by clicking theSTORE push button in the input box. This will open an input boxsimilar to that shown for the XYZ PLANES function. Enter the name tobe given to this set of cross sections and click on the APPLY pushbutton.

Once you have saved a cross-section definition, you may READ it forsubsequent viewing and analysis. When you click on the READ pushbutton as shown in the figure above, an input box will open for you toenter the name of the cross-sectional definition to be read.

The DEL push button in the input dialog box shown above, will deletethe plane definition which has been highlighted in the list.

You may close the ANYPLANE list by clicking the QUIT push button.

The figure shown here illustrates a the result of using ANYPLANE to

define and subsequently display a cross-section. You may alternatebetween the ANYPLANE input list and the PICTURE menu option toview alternative cross-sections.

VIEW


ISOSURFACEThis tool allows you to watch the progress of the mush zone duringcasting fill. To view an isosurfaceyou must define the upper and lowervalues to be used as the limits for theview. Once these limits are set, youmust then click on the PICTUREoption in the VIEW menu.

When you click on the ISOSURFACEpush button in the VIEW menu aninput box will be opened, as shown here. You define the limits of themushy zone by highlighting VAL1, placing the cursor in the Edit Value

input line, typing the desired value and pressing ENTER. You repeat this

process for VAL2. These actions will place the entered values in therespective positions in the input box. When you have entered both ofthese limits, click on the DONE push button to close the display.

Once these limits have been entered, you may click on the PICTUREoption in the VIEW menu to observe the progress of the specifiedmushy zone in the casting. The example shown here illustrates themushy zone. Notice that (according to the limits specified in thisexample) solidification has already begun in portions of the casting asseen in the extreme right side and bottom of the casting.

DISPLACEMENTThis option is only available for stress analysis problems. It allows youto view the deformed mesh in red superimposed on the original meshwhich is displayed in white.

REDRAWThis option redraws the image in the graphics display window. This isuseful for refreshing the graphics area.

VIEW


1 VIEWThis option is a rotary toggle button which allows you to specify 1, 2, or4 views of the model for concurrent display. You may describe up tofour different views of the model and the respective XYZ PLANES to bedisplayed for each view.

Viewing multiple views of the model is a three step process:

1. Defining the views: To describe a view, press 1, 2, 3, or 4 on the

keyboard. You will see the view number, which is displayed inthe lower left-hand corner of the work window will change tocorrespond with the number you pressed.

You may rotate or reposition the model to suit your needs. Youmay then specify the cross-sectional planes to be plotted forthis view. Concurrent views two through four may be defined inthe same manner by first pressing the appropriate number onthe keyboard.

2. Activating the number of concurrent views to be displayed: Click onthe 1 VIEW push button in the VIEW menu to select the desirednumber of concurrent views to be displayed. Successive clickson this push button will cycle through the number of views.

3. Viewing the PICTURE: After the views have been defined andactivated, click on the PICTURE push button in the VIEW menuto plot the displays.

As shown here, the work window is divided in quadrants, in thisexample four, to show the views which were defined.

VIEW


REPLAYThis option allows you to load and replay a picture file. When youselect this menu option, a file name inputbox is displayed. As shown here, youplace the cursor in the input line, type thefile name, and click on DONE. This willresult in the immediate action to load andplay the replay file.

You may close the file name input box by clicking the QUIT pushbutton.

Remarks The VIEW options of ViewCAST afford a variety of analytical tools forvisualizing the results of your ProCAST simulation. It is important tonote that you may move back and forth between the options of theVIEW menu as well as the STEPS, MATERIALS, and PARAMETERSfunctions of ViewCAST.

ViewCAST makes it easy to change starting times, time step values,the materials to be displayed, cross-sections, as well as other attributesof the results to be displayed. For example, clicking on any ViewCASTmenu bar push button during the PICTURE display, will stop the pictureand open the selected menu. Once you have completed the desiredchange, you can restart the display activity by clicking on the VIEWpush button and then click on the PICTURE menu entry.

Related Topics PAUSE, CONTOUR, VECTOR, STEPS, PARAMETERS, MATERIALS

PAUSE


PAUSEDescription PAUSE is a push button in the Main Function Banner which suspends

contour and/or vector plotting. When PAUSE is active, you may createreplay files or postscript printer files containing the views and resultswhich are being displayed. Plotting may be resumed by clickingPAUSE again.

The functions available from this menu will be discussed in this section.

Method PAUSE is activated by clicking on it. When PAUSE is activated, theoption buttons, shown here, will bedisplayed in the lower-right side ofthe work window. These optionbuttons provide the capability tocreate a replay file, using the SToption, and/or to create the postscript file, using the P option.

As shown here, when you select the ST function, a file name input boxwill be displayed. Tocreate a replay file,place the cursor inthe input line, typethe file name andclick on DONE. You may resume the animated display by clicking thePAUSE push button.

You may close the file input box without entering a file name by clickingthe QUIT push button.

The P option results in the immediate action to create a postscriptprinter file. Once the file has been created you may resume theanimated display by clicking the PAUSE push button.

Remarks PAUSE may be used to temporarily suspend the animated updating ofthe picture.

It is not necessary to resume the animation in order to make changes toparameters, steps, cross-sectional planes, or other capabilitiesavailable in ViewCAST. For example, if you pause the display anddecide to change the interval step value, you may click on the STEPSpush button in the Main Function Banner without first resuming thepicture display.

Related Topics CONTOUR, VECTOR, STEPS, PARAMETERS, MATERIALS, VIEW

USING INVERSE MODELING

USING INVERSE MODELING, PAGE 7 - 1

CHAPTER 8


Description The Inverse Modeling module of ProCAST allows you to determinethermophysical data or boundary conditions from simple well controlledtemperature measurements.

Method The INVERSE solver runs in a Unix session window. After you openthe session window, the INVERSE calculation can be started using thefollowing command at the session window prompt:

inve {prefix} [ -b ] ENTER

Prefix is a required parameter and you should enter the name of thisproject.

-b is a command line option which specifies that INVERSE will be run inthe background as a batch mode task. Do not use the UNIXampersand (&) option to run proinve in the background.

Remarks Inverse modeling allows you to use the thermal history generated byProCAST as an input for deriving thermophysical properties, initialconditions, or boundary conditions. In order to perform the selectedinverse calculations all other aspects of a problem must be set-up. Thismeans that information about the following components of the problemmust be defined. • geometry, • material properties, • interface heat transfers, • boundary conditions, • initial conditions, and • run parameters.

You may use menu options in the MATERIALS, INTERFACE,BOUNDARY CONDITIONS, and RUN PARAMETERS menus tospecify the component and properties to be calculated using the inversemethodology.

Once a problem has been configured in PreCAST, you should runDataCAST to check the model for errors. The prefixid.dat file

generated by PreCAST contains all of the inverse settings. In a mannersimilar to the PreCAST prefixd.dat file, the inverse settings file may be

modified manually with a text editor. The format of the prefixid.dat file

is described in Appendix K of this manual.



Operational procedures and standards at your installation may specifyadditional start-up requirements such as passwords, working directoryspecifications, and project or file naming conventions. Consult yourinstallation or network manager for these guidelines.

There are three ways to monitor the status of the Inverse Calculation. Monitoring the calculation is a good practice for checking to determinethat the calculation is stable and that convergence is progressing. Eachof these three methods for monitoring this progress are described here.Using the status utility

There is a small utility program which can be run to report the status ofthe INVERSE calculation. This utility may be started by opening a Unixsession window, setting the current directory to the directory containingthis problem’s prefix* files, and typing the following command at the

session window prompt:

statinve {prefix} ENTER

This utility prints the status of the calculation by indicating whether it isstill in progress or that it has been completed. It also providesadditional information which includes: the number of iterations alreadycalculated, the beta values of the last iteration, and the residual of thecurrent iteration.

The residual is the average temperature difference between themeasured and the calculated curves based upon an average of all thesteps and all the curves at the given iteration. The residual willdecrease towards zero and is a good way to see how the convergenceis reached.

Note: If the calculation was interrupted by the user, it willdisplay that the calculation is in progress.

Evolution of the beta values

The beta values obtained at each iteration are stored in the fileprefixir.dat. Accordingly, during the calculation, it is possible to use

PostCAST to visualize the evolution of each beta value from the firstiteration to the current iteration. From this plot, you can determine ifthe calculation is converging. The format of the file prefixir.dat is the

same as that of the measurement. Curve “I: of the file prefixir.dat

corresponds to the ith beta value.

The residual is stored as the last curve of the prefixir.dat file. You can

therefore graph the evolution of the residual as a function of theiterations.


USING INVERSE MODELING, PAGE 7 - 3

Comparison between the measurements and the calculated curves

The goal of inverse modeling is to find the best set of beta values withwhich the calculated temperature curves will match the measured ones.

At the end of each iteration, the calculated curves corresponding to thelocation of the measurement points are stored in the prefixic.dat file.

This file is updated at each iteration. You can use PostCAST tovisualize the comparison of the measured curves and the calculatedcurves by superimposing one on the other. During the first iteration thematch between these two will be poor. Subsequent iterations shouldimprove with the match at the end of the calculation being good.

Final Results

At the end of the calculation, the final beta values correspond to thevalues of the last iteration in the prefixir.dat file. The quality of the

convergence may be checked as described above and are consideredgood if the beta values are not changing much during the last iterationsand if the residual is small. Note that the residual is measured indegrees and a residual of “1" means that the average differencebetween the measured and calculated curves is one degree.

Depending upon the convergence tolerance which is chosen, it ispossible that the beta values stay almost constant but oscillate aroundan average value and the calculation will be continued until themaximum number of iterations specified is reached. Based upon theseinitial results, for subsequent inverse calculations, is possible to reducethe maximum number of iterations in order to reduce the computingtime required.

If the inverse calculation is performed in a networked environment, it isadvisable to run the calculation in a directory which is on the diskclosest to the calculating CPU. This reduces the disk access delaywhich may occur through the network. It is always possible to run thecalculation in the /tmp directory and then move the final results to the

home directory of the user.

Related Topics APPENDIX B, APPENDIX K, APPENDIX L




INSTALLING PROCAST

APPENDICES, PAGE A - 5

APPENDIX A

INSTALLING ProCAST

Create InstallationDirectory

Use the Unix system command to make a directory in which you willinstall ProCAST. The syntax for this command is:

mkdir / directoryname ENTER

The following example creates the directory “procast.”mkdir / procast ENTER

After the directory has been created, make it the active directory. Thesyntax for this command is:

cd /directoryname ENTER

The following example changes to the procast directory.cd /procast ENTER

Extract ProCAST files Mount the delivery tape and extract the files. The syntax for thiscommand is:

tar xvf /dev/ tapeunitname ENTER

The following example extracts the files from the tape unit “rst8.”tar xvf /dev/ rst8 ENTER

This should create two subdirectories called BIN and LIB .

Establish AccessAuthorizations

The BIN directory must have read and execute permissions for allauthorized users. The files in the LIB directory, the LIB directory andthe BIN directory need read and write permissions for all authorizedusers. The following example changes the permission code for the filesin the BIN directory.

chmod 555 BIN/* ENTER (Gives read + execute)

The following example changes the permission code for the files in theLIB directory.

chmod 666 LIB/* ENTER (Gives read + write)

The following example changes the permission codes for the BIN and LIB directories.

chmod 777 BIN LIB ENTER (Gives read + write +

execute)To perform these commands, you must be the owner of the files anddirectories. The superuser can use the chown command to assign thecorrect ownership for these files and directories.

INSTALLING PROCAST

PAGE A - 6 PROCAST USER’S MANUAL

Modify PATH Statement The following lines should be put into the .cshrc file of each user if theyare using the C shell:

setenv ProPATH /procast /LIB

setenv ProBIN /procast/BINAlternatively, if the Bourne shell is being used, the following linesshould be put in the .profile file:

ProPATH=/procast /LIB

export ProPATHProBIN=/procast/BIN

export ProBINYou should make sure that the path names are the same as theinstallation directory.

Establish PATH The path “/procast/BIN” needs to be in the set path command in eitherthe .login or .cshrc files of all users or in the PATH command in the.profile file. You should make sure that the path names are the sameas the installation directory.

Unlock ProCAST To unlock ProCAST, set the ProPATH environment variable, run theunlocking program, and supply the unique unlock code.

The syntax for this command is as follows:pro_enable unlockcode ENTER

The unlock code will be provided to you by UES Software and it iscalculated for your unique environment.

PROCAST FILE USAGE

APPENDICES, PAGE B - 1

APPENDIX B

ProCAST FILE USAGE

This appendix presents a profile of the file usage for each component of ProCAST. Presented in tabularform, the name of the ProCAST component is displayed in the top of each table. Input files are listed incolumn one. The file description for the input file is presented in column two. Output files are listed incolumn three. File descriptions for the output files are presented in column four if they are different thanthe descriptions of the input files.

The file usage for each ProCAST component are shown below.

PreCAST

Input Files Description Output Files Description

prefix.out PATRAN or ANVIL neutral file which describes the model

geometry

prefixd.dat Problem description file

prefix.unv IDEAS universal file which describes the model geometry prefixp.dat Problem run file

prefix.ans ANSYS node and element files pre.err Error log file

prefix.14 ANSYS node and element files

prefix.15 ANSYS node and element files

pre.scr Menu descriptions for PreCAST

pre.edf Editor descriptions for PreCAST

promat.db ProCAST supplied material properties database

matl.db User's material properties database matl.db

matl.idx User’s material properties index matl.idx

micro.db Micromodel material properties database micro.db

micro.idx Micromodel material properties index micro.idx

intf.db Interface heat transfer coefficients database intf.db

intf.idx Interface heat transfer coefficients index intf.idx

bndry.db Boundary conditions database bndry.db

bndry.idx Boundary conditions index bndry.idx

encl.db Enclosure properties database encl.db

encl.idx Enclosure properties index encl.idx

stress.db Stress material properties database stress.db

stress.idx Stress material properties index stress.idx

DataCAST



PROCAST FILE USAGE

DataCAST


PAGE B - 2 PROCAST USER’S MANUAL

prefixd.out Printed output from DataCAST

prefixg.unf Unformatted geometry file

prefixd.unf Unformatted time step file

prefixt.unf Unformatted temperature file

prefixu.unf Unformatted u---velocity file

prefixv.unf Unformatted v---velocity file

prefixw.unf Unformatted w---velocity file

prefixp.unf Unformatted pressure file

prefixk.unf Unformatted turbulent kinetic energy file

prefixe.unf Unformatted turbulent dissipation rate file

prefixf.unf Unformatted fluid fraction file

prefixq.unf Unformatted heat flux file

prefixo.unf Unformatted file of nodal coordinate offsets for enclosure

elements

prefixs.unf Unformatted file of nodal coordinate offsets for moving

solid elements

ProCAST


prefixp.dat Run parameters

prefix�.unf Unformatted files, where � =g, d, t, u, v, w, p, f, k, e, q, o, s

as in DataCAST

prefix�.unf

prefix.ctoc Unformatted radiation view factor information prefix.ctoc

prefix.fic Fictitious mold information prefix.fic

prefix.sel Highest filled element when FREESF = 2 prefix.sel

prefix.fom Lost foam information prefix.fom

prefixa.unf Unformatted freezing time file prefixa.unf

prefixb.unf Unformatted dissolved gas bubble file prefixb.unf

prefixc.unf Unformatted macro porosity file prefixc.unf

prefixfs.unf Unformatted fraction solid file prefixfs.unf

prefixr.unf Unformatted compressible density file prefixr.unf

prefixn.unf Unformatted non-Newtonian shear rate and viscosity file prefixn.unf

prefixv.unf Unformatted turbulent viscosity file prefixtv.unf

prefixeng.unf Unformated electric potential file prefixeng.unf

prefixmg.unf Unformatted magnetic potential file prefixmg.unf

PROCAST FILE USAGE

ProCAST



prefixx.unf Unformatted x displacement file prefixx.unf

prefixy.unf Unformatted y displacement file prefixy.unf

prefixz.unf Unformatted z displacement file prefixz.unf

prefixgs.unf Unformatted stress file prefixgs.unf

prefixgn.unf Unformatted effective plastic strain file prefixgn.unf

prefixst.unf Unformatted total load file prefixst.unf

prefixsr.unf Unformatted stress source term file prefixsr.unf

prefixcp.unf Unformatted contact pressure file prefixcp.unf

prefixp.out Printed output from

ProCAST

prefix.serr Row sum error view factor

file

prefix.view Group to group view factor

file

prefix.vf Face to face view factor file

PostCAST


prefix�.unf Unformatted files, where � = g, d,

t, u, v, w, p, f, q as in DataCAST

post.scr Screen descriptions for

PostCAST

post.edf Editor descriptions for

PostCAST

prefix.serr Row sum error file

prefixe.ntl Row sum error file for postprocessing use

prefixfs.unf Unformatted fraction solid file

prefixg.ntl Geometry neutral file for postprocessing use

prefixi.ntl Isochron results neutral file

prefixm.ntl Mapping function results neutral file

prefixm.unf Mapping function results unformatted file

prefixl.ntl Feeding length results neutral file

prefixl.unf Feeding length results unformatted file

prefixr.ntl Radiation model geometry file for model check-out

prefix�.ntl Dependent variable results neutral file, where � = t, u, v,

w, p, q

prefixi.log Temperature log

PROCAST FILE USAGE

PostCAST



prefixm.log Mapping function log

prefixl.log Feeding length log

prefix�.log Analysis time log for use with dependent variable results

neutral files, where � = t, u, v, w, p, q

post.err

prefix.tt Temperature, velocity, pressure, or fraction solid versus

time file

ViewCAST


prefix�.unf Unformatted files, where � = g, d, t, u, v, w, p, f, q as in

DataCAST

view.scr Screen descriptions for ViewCAST

view.edf Editor descriptions for ViewCAST

prefixi.ntl Isochron results neutral file

prefixm.ntl Mapping function results neutral file

prefixi.log Temperature log for use with the isochron neutral file

prefixm.log Mapping function log for use with the mapper neutral file

prefix.serr Row sum error file

prefix.view Group to group view factor file

view.color Color spectrum file ( contains RGB values ) view.color

prefix�.unf Unformatted files, where � = a, b, c, r, n, tv, mg, x, y, z, gs,

gn, as in ProCAST

INVERSE



prefixim.dat Contains the node numbers or node

coordinates corresponding to the

location of the measurement points.

prefixid.dat Contains the inverse settings.

prefixir.dat Contains the evolutions of the beta values along the

iterations. It also contains the evolution of the

residual.

prefix.stat Contains information on the status of the inverse

calculation.

PROCAST FILE USAGE

INVERSE



prefixic.dat Contains the calculated temperature evolutions (of

the last calculated iteration) corresponding to the

locations of the measured curves.

prefix.list This file is created, if the inverse calculation is

performed in the background, to store the printout

which normally appears on the workstation screen.

This file is only written when the workstation buffer is

unloaded.

PROCAST FILE USAGE



MATHEMATICAL FORMULATIONS

APPENDICES, PAGE C - 1

'cp T t

/ [ k / T ] q ( x ) 0 C.1.1

/

x�

y�

zC.1.2

' H T

T t

/ [ k / T ] q(x) 0 C.1.3

H(T ) PT

0

cp d - � L[ 1 fs (T )] C.1.4

APPENDIX C


Section 1: Energy Equations

1. Transient linear

whereT = vector of nodal temperatures

q(x) = spatially varying volumetric heat source

in Cartesian coordinates' = constant densitycp = constant specific heat

t = time

k = constant conductivity

2. Transient non-linear conduction

where' = '0 f(T), constant or temperature dependent density

k = k0 f(T), constant or temperature dependent conductivity

H = enthalpy, a function of temperature, which encompasses the effects of specific

and latent heat

L = latent heat

fs = fraction solidified

3. Transient laminar advection-diffusion


PAGE C - 2 PROCAST USER’S MANUAL

'0H0t

� 'ui0H0xi

/( k / T ) q 0 C.1.5

'0H0t

� 'ui0H0xi

/ k �

µT

)T

/ T q 0 C.1.6

0'

0t�

0('ui)

0xi

0 C.2.1

0('ui )

0t�

0

0xj

(uj 'ui � p i j )i j ) 'gi C.3.1

)i j µ0ui

0xj

�

0uj

0xi

23

µ0uk

0xk

i j � µ T

0ui

0xjC.3.2

whereui = fl ui,liq = component of superficial velocityfl = fraction liquid

ui,liq = actual liquid velocity

4. Transient turbulent advection-diffusion

whereµT = eddy viscosity)T = turbulent Prandtl number

Section 2: Continuity Equation

Conservation of mass is enforced through the continuity equation:

Section 3: Momentum Equations

The full Navier-Stokes equations are given by:

where)ij = Stokes viscous stress tensor including the Reynolds stress approximation and

assuming the bulk viscosity is negligible

ij = Kronecker deltap = pressuregi = gravitational acceleration

Expanding the differentials on the advection term and using the continuity equation to simplifyyields:



'0ui

0t� 'uj

0ui

0xj

�

0

0xj

(p i j )i j ) 'gi C.3.3

'0ui

0t� 'uj

0ui

0xj

�

0

0xj

p ij (µ � µT)0ui

0xj

'gi µK

ui C.3.4

K

f 3l

5 M 2s (1 fl )

2

Ms 6�Dp

C.3.5

0('k)0t

� uj0('k)0xj

0

0xj

µT

)k

0k0xj

µTG '� C.4.1

Assuming that the spatial derivatives of viscosity are small and that the fluid is nearlyincompressible, many terms in the viscous stress tensor can be neglected. A source term isadded to the standard momentum equation to simulate the effect of flow in mushy regions and todrive the velocities to zero when the material is fully solid. This gives the final form of themomentum equation as used in ProCAST:

whereK = permeability

The permeability is calculated using the Kozeny-Carmen equation

whereMs = surface to volume ratio of solid structure

� = shape factorDp = characteristic dimension

Assuming conically shaped dendrite arms with an average diameter of 100 microns, Ms = 600cm-

1

Section 4: Turbulent Kinetic Energy

The conservation equation for turbulent kinetic energy is given by:

where



k

12

(u 12� v 12

� w 12 )

u 1 ,v 1 ,w 1 fluctuating velocity components

)k Prandtl number of turbulent kinetic energy, typically set to 1.0

G

0ui

0xj

�

0uj

0xi

0ui

0xj

turbulence generation rate

� turbulence dissipation rate

0('�)0t

� uj0('�)0xj

0

0xj

µT

)�

0�

0xj

�

k(C1µT G C2 '�) C.5.1

µT

Cµ 'k 2

�C.6.1

- �� C.7.1

Section 5: Turbulence Dissipation Rate

The differential equation for calculating the dissipation rate is as follows:

where)� = Prandtl number for turbulence dissipation rate, typically set to 1.3.

Default values are: C1 = 1.44 and C2 = 1.92

Section 6: Eddy Viscosity

The turbulent eddy viscosity is calculated from the turbulent kinetic energy and dissipation rate asfollows:

whereCµ = 0.09 is a default

Section 7: Non-Newtonian

With non-Newtonian flow, the shear stress is a nonlinear function of the strain rate, represented by



� �� (�0 �

�) [1 � (��)a ]

n1a C.7.2

��

12 M

iM

j��i j��j i

.5

12

(�� : ��

.5

C.7.3

�.

0u0x

�

0u0x

0v0x

�

0u0y

0w0x

�

0u0z

0u0y

�

0v0x

0v0y

�

0v0y

0w0y

�

0v0z

0u0z

�

0w0x

0v0z

�

0w0y

0w0z

�

0w0z

C.7.4

X : 0

0x(-xx ) � 0

0y(-yx ) � 0

0z(-zx )

Y : 0

0x(-xy ) � 0

0y(-yy ) � 0

0z(-zy )

Z : 0

0x(-xz ) � 0

0y(-yz ) � 0

0z(-zz )

C.7.5

The current version of ProCAST contains an implementation of the Carreau-Yasuda correlation in whichthe viscosity is given by

where�0 = zero strain rate viscosity��

= infinite strain rate viscosity� = phase shift coefficienta = Yasuda coefficient

n = power law coefficient

In ProCAST, all five of these coefficients can be constants or functions of temperature.

The strain rate, as it appears in the correlation, is taken to be the magnitude of the strain ratetensor:

where

The shear force terms in the momentum equations take on the following form:



0

0x�

0u0x

�

0u0x

�

0

0y�

0v0x

�

0u0y

�

0

0z�

0w0x

�

0u0z

0

0x�0u0x

�

0

0y�0u0y

�

0

0z�0u0z

�

0

0x�0u0x

�

0

0y�0v0x

�

0

0z�0w0x

C.7.6

0

0x�0u0x

�

0

0y�0v0x

�

0

0z�0w0x

�0

0x0u0x

�

0v0y

�

0w0z

�

0u0x

0�

0x�

0v0x

0�

0y�

0w0x

0�

0z

C.7.7

/x V # /�� C.7.8

0 2� 0u0x

2

�

0v0y

2

�

0w0z

2

�

0v0x

�

0u0y

2

�

0u0z

�

0w0x

2

�

0v0z

�

0w0y

2C.7.9

Using the x-momentum term as an example and the stress-strain relationship shown previously, thefollowing expansion is possible:

The first three terms on the right hand side are the same as appear in the NewtonianNavier-Stokes formulation. The last three terms can be simplified somewhat by expanding themfurther:

Assuming that the densification rate, 0' / 0t , is negligible, then the first term on the right hand

side vanishes from continuity. This leaves a non-Newtonian contribution to the shear force ofthe form:

Similar terms arise for the y and z momentum equations as well.

A dissipation term is also added to the energy equation of the form:



T (x,0) T0 (x)u (x,0) u0 (x)v (x,0) v0 (x)w (x,0) w0 (x)p (x,0) p0 (x)

C.8.1

T (x) Td (x) f (t), on 1 C.8.2

V (x) Vd (x) f (t), on 1 C.8.3

P(x) Pd (x) f (t), on 1 C.8.4

Section 8: Initial and Boundary Conditions

1. Initial conditions

2. Fixed temperature boundary condition

where1 = some subset of the total boundary

Td(x) = specified temperature vector

f(T) = time function

This is also known as a Dirichlet boundary condition. In a steady state problem, there is no timefunction modifying the specified temperatures.

3. Fixed velocity boundary condition

whereVd(x) = specified velocity vector

f(t) = time function

4. Fixed pressure boundary condition

wherePd(x) = specified pressure vector

f(T) = time function



�(x) �d (x) f (t), on 1 C.8.5

�

12

(.05V )2C.8.6

� (x) �d (x) f (t), on 1 C.8.7

� cµ �

32 / � C.8.8

5. Fixed turbulent kinetic energy boundary condition

where�d(x) = specified turbulent kinetic energy vector

f(t) = time function

By default, the turbulent kinetic energy is taken as 5% of the total kinetic energy of the flow, thatis

whereV = total velocity magnitude

6. Fixed turbulent dissipation rate boundary condition

where�d(x) = specified turbulent dissipation rate vectorf(T) = time function

By default, the turbulent dissipation rate is calculated as

where� = a characteristic length which is assumed to be 1.0% of the smallest dimension of

the openingcµ = the run parameter CMU



k / T # n qn f (t), on 2 C.8.9

qn specified heat fluxn unit vector normal to the surface2 some subset of the total boundary

k / T # n h f (t)g(T ) [T Ta], on 2 C.8.10

k / T # n ) � g (T) [T 2� T 2

a ] [T � Ta ] [T Ta ], on 2 C.8.11k / T # n ) � g (T) [T 2� T 2

a ] [T � Ta ] [T Ta ], on 2 C.8.11

7. Specified heat flux boundary condition

where

This is also known as a Neumann boundary condition.

8. Convective heat flux boundary condition

whereh = convection (film) coefficient

g(T) = temperature functionTa = ambient temperature, which can be a function of time.

9. Radiation heat flux boundary condition

where) = Stefan-Boltzman constant� = emissivity

This is the "simple" radiation model in which it is assumed that there is only one ambienttemperature present. Thus, the view factor is equal to one.



qnet, i qout, i qin, i C.9.1

qout, i ) �i T4i � (1 �i ) qin, i C.9.2

qin, i MN

j 1

Fij qout, j C.9.3

Fi j 1Ai

Aj Ai

cos �j cos �i

%r 2d Ai d Aj C.9.4

Section 9: The View Factor Radiation Model

For the more complex view factor radiation capability, ProCAST uses a net flux model. Rather thantracking the reflected radiant energy from surface to surface, an overall energy balance for eachparticipating surface is considered.

At a particular surface i, the radiant energy being received is denoted qin, i. The outgoing flux is qout, i.

The net radiative heat flux is the difference of these two.

Utilizing the diffuse, grey-body approximation, the outgoing radiant energy can be expressed as

The first term in (C.9.2) represents the radiant energy which comes from direct emission. The secondterm is the portion of the incoming radiant energy which is being reflected by surface i.

The incoming radiant energy is a combination of the outgoing radiant energy from all participatingsurfaces being intercepted by surface i. Specifically, the view factor Fi-j is the fraction of the radiant

energy leaving surface j which impinges on surface i. Thus,

whereN = total number of surfaces participating in the radiation model and the view factors

are calculated from the following integral.

whereAi = area of surface i�i = polar angle between the normal to surface i and the line between i and jr = magnitude of the vector between surfaces i and j

Traditionally, (C.9.4) is evaluated by numerical integration, either in the form shown or convertedinto an equivalent line integral. In ProCAST, the view factors are computed using a proprietarytechnique.



qin, i 1

1 �i

[qout, i ) �i T4i ] C.9.5

MN

j 1[ i j (1 �i ) Fi j ] qout, j )�i T

4i C.9.6

Ai

(1 �i )C.9.7

MN

j 1

Ai

(1 �i ) i j Ai Fi j qout, j

�i Ai

(1 �i )) T 4

i C.9.8

qnet, i �i

1 �i

[)T 4i qout, i ] C.9.9

Solving (C.9.2) for qin, i yields:

Combining (C.9.5) with (C.9.3) gives a relationship involving the outgoing radiant fluxes only. These outgoing fluxes are known as radiosities. The final form is

The Kronecker delta, i,j, has been included to incorporate the diagonal term. Since there are equations of the form (C.9.6), a simultaneous solution is required for a large non-symmetricsystem. Because of the reciprocity relation, Ai Fi-j = Aj Fj-i (C.9.6) can be transformed into a

symmetric form which is more economical to solve. Multiplying (C.9.6) by

yields:

which is solved for the vector of radiosities, qout, j. The net radiant flux is obtained by combining

(C.9.1) and (C.9.5), giving

This heat flux then appears as a boundary condition for the heat conduction analysis inProCAST.



T �

( x, t ) Ni(x) Ti(t) C.10.1

C �T � K T F C.10.2

Cij

6

'dHdT

Ni Nj d6 C.10.3

Kij

6

/ Ni # (k / Nj ) d6 �

2

h Ni Nj d 2 C.10.4

Fi

2

Ni (q hTa ) d 2 C.10.5

�T time derivative of the vector of nodal temperatures

Section 10: Finite Element Discretization

ConductionThe solution domain, 6, is divided into a set of non-overlapping subregions which completely fill thespace. In each of these elements, temperatures are interpolated from values at discrete nodal locations. This yields a temperature field which approximates the exact solution.

whereNi = interpolating or "shape" functions

Ti = nodal values of temperature

Repeated indices in a term indicate the application of the Einstein summation convention. The particularshape functions employed are a consequence of the element types. Currently, ProCAST supports linearbrick, tetrahedral, and wedge elements and quadratic tetrahedral elements.

The following development will concentrate on the non-linear, transient heat conduction case. Insertingthe approximate solution (C.10.1) into the governing field and boundary condition equations (C.1.3),(C.8.9--C.8.11), produces a residual error. This error is minimized in an average sense by the Method ofWeighted Residuals, applying the Galerkin procedure of using the shape functions, Ni, as the weighting

functions. This results in the symmetric matrix system

whereC = capacitance matrix with terms

K = conductivity matrix with terms

F = source vector with terms

In (C.10.4) and (C.10.5), h combines the effects of Newtonian and radiation heat transfer.



K K �

3

hc Ni Nj 12

Nk d 3 C.10.6

Ni'

fl

Nj

0uj

0tdV � Ni

'

f 2l

uk

0uj

0xk

dV Ni0

0xk

µ1fl

0(Nj uj)

0xk

dV

Ni 'gj dV Ni0p0x

dV Niµ1K

Nj uj dV

C.10.7

The integrations are performed on an element-by-element basis and assembled to form the globalmatrices. Typically, these integrations are too complex to perform analytically. Recourse is taken tonumerical integration techniques, which involve an isoparametric mapping to a local, element-basedcoordinate system. Details of this approach can be found in any standard finite element text book.

One feature of ProCAST which particularly enhances its utility for casting simulations is a coincidentnode technique for handling the mold-metal interface and parting surfaces. Along the desired thermalbreak interface, 3, a second set of spatially coincident nodes is added to the original nodal topology. The original nodes would be assigned to the elements on one side of the interface, the metal forexample, and the second set to the other side. A Newtonian heat flux relation between the two sets isincorporated into the conductivity matrix by an integration on 3,

where hc coincident interface heat transfer coefficient. This may be a function of time and/or

temperature. Node k is coincident to node j.

The advantages of using coincident nodes rather than thin elements at the interface are that it is moreeconomical in terms of CPU time, and it is easier to specify when using commercial preprocessingpackages to create the finite element mesh. In ProCAST, this technique will automatically be employedat the interface of dissimilar materials if the user desires.

Momentum

Applying Galerkin's method to the momentum equation gives the following expression:

whereµ1 = (µ + µT)



Ni'

f 2l

uk

0(Nj uj)

0xk

dV �'

f 2l

us0u0s

Ni dV C.10.8

Ni0

0xk

µ1fl

0(Nj uj )

0xk

dV

0Ni

0xk

µ1fl

0Nj

0xk

uj dV � Nj

0(Nj uj)

0xk

µ1fl

# ndS C.10.9

M�u � (D � A � C )u � Sg � Sp 0 C.10.10

Mij '

fl

Ni Nj dV

Dij µ1fl

0Ni

0xk

0Nj

0xk

dV

Aii 's

f 2l

us1�s P Ni dV

Cij µ1K

Ni Nj dV

Sg, i P Ni 'gk dV

Sp, i Ni0p0xk

dV

C.10.11

A streamline upwind approximation is used in the advection term:

whereus = streamline velocity

s = streamline coordinate

The divergence theorem is applied to the diffusion term of the momentum equation so that the weightingfunctions and interpolating functions will be of the same order.

The final discretized momentum equation has the form:

where



M (u n � 1 u n )�t

� ( D � A � C ) [�u n � 1� (1 �)u n ] � Sg � Sp 0

(M/�t)u n � 1� ( D � A � C ) �u n � 1

(M/�t)u n ( D � A � C ) (1 �)u n

Sg Sp

[(M/�t) � ( D � A � C ) � ] �u n � 1 ( D � A � C )u n

Sg Sp

C.10.12

Bii ui M Bij uj � fi Ni0p0x

dV

ui u

1Bii

Ni0p0x

dV u Ki0p0x

u

M Bij uj � fi

Bii

, Ki P Ni dV

Bii

C.10.13

Ni0'

0t�

0('uk )

0xk

dV

Ni0'

0tdV � Ni ( 'uk ) # n dS 'uk

0Ni

0xk

dV 0

C.10.14

' uk Kk0p0xk

0Ni

0xk

dV Ni ('uk ) # n dS � Ni0'

0tdV

'Kk0p0xk

0Ni

0xk

dV ' uk

0Ni

0xk

dV Ni ('uk) # n dS Ni0'

0tdV

C.10.15

Using a two level time stepping method and solving for a correction value yields the following equationform:

Pressure

If the discretized momentum equations are considered in terms of the resulting coefficients, Bij, andnodal velocities, uj, then the effect of pressure gradients may be separated out as:

It has been assumed momentarily that the pressure gradient is constant under the integral. First, thecontinuity equation is discretized using Galerkin's method of weighted residuals and Green's Lemma:

Substituting the velocity correction relation above into the discretized continuity equation yields thepressure equation:



D� p n � 1 Dp n

� Su � S' C.10.16

Dij 'Kk

0Ni

0xk

0Nj

0xk

dV

Su, i 'uk

0Ni

0xk

dV

Ss, i Ni ( 'uk ) # n dS

Sp, i Ni0'

0tdV

C.10.17

[C � � t � K ] T n � 10 [C � t (1 �) K ]T n

� F C.11.1

C, K, and F are evaluated with intermediate temperature values at time level nT n � 1

0 predicted temperature vector�t current time step

[C � �t � K ] T n � 1p [C �t (1 �) K ]T n

� F C.11.2

C, K, and F are evaluated with intermediate temperature values T~

T~ � T n � 1p � (1 �) T n , � � [0.0,1.0]

T n � 1p corrected temperature vector

This is solved in a correction form as:

where:

Section 11: Time Stepping Algorithm

The first order differential equation system which is obtained from the finite element spatialdiscretization, (C.10.2), is numerically integrated by a two level predictor-corrector scheme.

Predictor Step

where

Corrector Step

where



� 0.0, forward difference, explicit

�

12

, central difference

�

23

, Galerkin

� 1.0, backward difference, fully implicit

The solution vector is corrected until either the maximum of number of corrections is reached or themaximum difference in temperatures between two successive iterations is less than a user-specifiedconvergence criterion. This algorithm automatically adjusts the time step according to the number ofcorrector iterations that were required on the previous step. If the maximum number of corrections isexceeded, the time step is reduced and the step attempted again.

The value of �, selected from the range of 0.0 to 1.0, determines the nature of the algorithm. Somefamiliar two-level schemes which may be recovered are as follows:

If capacitance matrix is lumped with the forward difference scheme, the global system matrix becomesdiagonal and is therefore rapidly inverted. However, the time step restriction to ensure stability can beunacceptably severe. For unconditional stability, it is required that .� �

12

The central difference scheme is the only two-level method with second order accuracy and is thusrecommended in general. However, it also has a time step restriction to prevent oscillation. The timestep is governed by the eigenvalue spectrum of the system matrix. In a typical casting simulation, thehigh frequency modes, which correspond to large eigenvalues, quickly decrease in amplitude. Thispermits a gradual increase in the time step from a small initial value without producing oscillations.

The backward difference scheme has no stability or oscillatory time step restriction and is thereforealways "safe." However, it is only first order accurate and tends to smooth out results which should besharply varying.

An Implicit-Explicit Algorithm is available, based on this two-level scheme. It is implemented simply byassigning values of � independently to each element. For � = 0.0, the element capacitance matrix islumped, contributing only diagonal terms to the system matrix. This speeds up the solution of the systemwhen a profile based solver is used. In casting simulations, it is often possible to treat the mold elementsexplicitly because of the large difference in material properties between metal and mold. A substantialreduction in computational costs can be realized if this technique is employed.



/ × H J �

0D0t

C.12.1

/ × E

0B0t

C.12.2

/ # B 0 C.12.3

/ # D ' C.12.4

B µH C.12.5

D �E C.12.6

J )E C.12.7

Section 12: Electromagnetics

We start with Maxwell's Equations:

whereE = the electric field intensityJ = the current densityD = the electric flux density (displacement flux)H = the magnetic field intensityB = the magnetic flux density' = the charge density

Assuming linear material properties, these additional relations are also considered:

whereµ = the magnetic permeability� = the permittivity) = the electrical conductivity

For the induction heating problem, it is convenient to let the magnetic flux density be represented by the



B / × A C.12.8

/ × E / × /1 / × 0A0t

/ × 0A0t

C.12.9

/ × 1µ

( / × A) ) / 1 )0A0t

J0 e j7 t )

0A0t

C.12.10

/ × 1µ

( / × A0 ) J0 ) j7 A0 C.12.11

/ × 1µ

( / × A0 )

1µ/ ( / # A0 ) 1

µ/

2 A0) � /1µ

× ( / × A0)

1µ/

2 A0

C.12.12

1µ/

2A0 ) j7A0 � J0 0 C.12.13

curl of a magnetic vector potential,

Therefore, Equation C.12.3 is automatically satisfied. Also, we will ignore the displacement flux, D = 0,

so Equation C.12.4 is satisfied.

Considering Equations C.12.2 and C.12.8, if , thenE / 1

0A0t

thus satisfying Equation C.12.2. Equation C.12.1 is all that remains to be satisfied. SubstitutingEquations C.12.5 and C.12.8,

Assuming that A = A0 e j7t with the same frequency as the driving current, then

Expanding the left hand side and assuming that the magnetic permeability is constant within an elementyields,

Therefore, the final equation used to determine magnetic potential is,



Magnetic field, B / × AEddy current, Je )j7 ALorentz force, Fl Je × B

Eddy heating, Qe 12)72

A 2

div ) � b 0 in 6

) # n t on )

u u on u

C.13.1

g (u) � 0

tN (u) n # ) # n � 0 on c

tN (u) g (u) 0

C.13.2

h 1. / 1h0

�

gkair

C.13.3

This is solved numerically as three systems of equations in the X, Y, and Z directions, with real andimaginary components. Other quantities of interest can be derived from the magnetic vector potential:

Section 13: Stress Analysis

Governing equations

where) = the stress tensorb = the body forcesn = the surface unit normal� = the surface tractionÅ = the prescribed displacements

Thermal-Mechanical Contact

Mechanical constraint:

whereg = the interface gap

tN = the normal surface traction

= the contact surface

Modification of interface heat transfer coefficient

Variational Formulation



P6

) # grad ( u)d6 P6

b # u d6 P)

t # u d

� Pc

< �k� !g(u) > n # u d 0

C.13.4

6

B T ) d6

6

N T b d6

)

N T t d �

c

�k � 1N T n d 0 C.13.5

6

B TD ��B d6 � � !N Ts Ns

n

�u n � 1

6

B T )nd6

6

N T bd6

6

N T t d � � �k N Ts

n

u n � 1 u n

� �un � 1

C.13.6

where�k + 1 = � �k + ! g(u)� the augmented Lagrangian multiplier

! = the penalty number�x� = ½ (x + x )

Finite Element Discretization

Linearization of this equation yields:

whereD** = the consistent tangent matrix described later.



) D (� �T ) C.13.7

�

12

/ u � ( / u)TC.13.8

�T � (T) I� T C.13.9

�� e� ��p

� ��T C.13.10

�) D ( �� p ) C.13.11

��p ��

0f0)

C.13.12

�� the plastic flow parameter

Stress Calculation

Elastic

whereD = the elasticity matrix containing material properties (Young's modulus, E, and

Poisson ratio, � )� = the thermal expansion parameter

�T = the temperature change

Inelastic

Flow rule

where



�� 1 ( f ) C.13.13

f ( ),T,� ) F ( ) ) � (� p, T ) 0 C.13.14

F ( ) ) 32

(s : s )1/2 C.13.15

s )

13

(tr)) I C.13.16

� H(T) � p� Y0 (T ) C.13.17

� p

t

0

23

� ��p� d - C.13.18

General Form

Yield Function ( Von Mises )

where the deviatoric stress is given by

Linear hardening rule

where H is the linear hardening parameter, Y0 is the initial yield stress, and the effective plastic strain isgiven by



� � ( �0 � � p ) m C.13.19

�0

E�

1m 1 C.13.20

1 ( f ) f� 0 C.13.21

��

1�1 ( f ) C.13.22

1 (f ) f�

N

C.13.23

1 (f ) eM f

� 1 C.13.24

Power law hardening rule

where �0 is the initial yield strain given by

� is a strength parameter and m is the hardening exponent

Plasticity

Visco-plasticity

where, 1/� is the viscosity and

or



Rn � 1 ��n � 1 D 1�)n � 1 ��n � 10f0)

n � 1 0 C.13.25

rn � 1 � � �n � 1 � t1( fn � 1 ) 0 C.13.26

D �0f0)

�t d1df

0f0)

T

A

j

)

(��)

j

R

r

j

C.13.27

D �

D 1� � �i 0

2f

0)2C.13.28

A � � �t d1df

0�

0� p

0� p

0(��)C.13.29

)j � 1n � 1 )

jn � 1 � ) j C.13.30

D ��

D �

D �0f0)

0f0)

T

D �T A �

0f0)

T

D �0f0)

1

C.13.31

Radial return mapping algorithm

Integrating Equations C.13.11 and C.13.13 by a backward Euler method,

Solving by Newton-Raphson yields the system of simultaneous equations,

where

The total stress is then updated by,

Finally, the consistent tangent matrix in Equation C.13.6 can be derived from Equation C.13.27,

Section 14: Preconditioned Conjugate Gradient Solver



xi x0 � �1 p1 � �2 p2 � . . . � �i pi C.14.1

r0 b Ax0

p1 r0C.14.2

�i ( ri 1 , ri 1 )

( pi , Api )C.14.3

1(xi ) 12

( xi , Axi ) ( b T xi ) C.14.4

xi xi 1 � �i pi

ri ri 1 �i ApiC.14.5

The conjugate gradient method is a semi-direct scheme for finding the solution to the positive definite,symmetric system Ax = b. It does this by building up the solution in steps by the linear combination of a

set of independent, A-conjugate basis vectors pi, called search vectors. Thus

A-conjugate means that the inner product (pi, Apj) = 0, I g j . The term "semi-direct" refers to the finite

termination property, i.e., that the method is guaranteed to converge to the exact solution in N steps inthe absence of numerical round-off, where N is the degree of the matrix A. If the conjugate gradient

method actually took that many steps, it would not be competitive with Gaussian elimination solvers. Itsutility derives from the fact that a sufficiently accurate solution may be obtained in far fewer steps. Inother words, it can be used as an iterative solver. This is particularly important for the large, sparseequation systems that occur in finite element analyses. CPU savings of up to 50% over direct solversare possible.

A complete development of the conjugate gradient method is rather lengthy, but we will provide asummary of how the unconditioned scheme works for the sake of completeness.

An initial guess, x0, is chosen either from the initial condition or the result of the previous time step. The

initial residual is computed and used as the beginning search vector.

For steps i = 1, ... N-1:

The formula for �i is derived from the minimization of the functional

with respect to �i. This is equivalent to finding the value of � which minimizes the residual error, giventhe search vectors available so far.



�i ( ri ,ri )

( ri 1 , ri 1)

( ri , Api )

(pi , Api )

pi � 1 ri � �i pi

C.14.6

( ri 1 , ri 1 ) ( ri , ri ) C.14.7

P T P M 1� A 1 C.14.8

( PAP T ) PbCy d C.14.9

C PAP T

y P T

d PbC.14.10

These last two steps are the improvement in the estimate of the solution vector xi and the reduction in

the residual error ri. At this point, the norm of the residual error, (ri, ri), is calculated and compared with

the convergence criterion �. If (ri, ri) > �, continue in the loop.

In the calculation of �i, the first form is used in practice, but the second is perhaps more indicative of itsfunction. The next search vector is chosen so that it will be A-orthogonal to the previous vector, andthereby to all prior ones. The direction of the new search vector is that of the latest residual with allcomponents aligned with previous search vectors subtracted out.

End of loop.

When viewed as an iterative technique, the rate of convergence of the conjugate gradient method isgoverned by the condition number of the matrix A. The condition number is the ratio of the maximum

eigenvalue to the minimum. Thus, if A is the identity matrix, the condition number would be one, and the

CG solver would converge in one step. The goal of preconditioning is to transform the matrix system sothat the new coefficient matrix has a condition number close to one. A conditioning matrix P is chosen

such that

Pre and post-multiplying the system Ax = b by P,

where



zi P T Pri M 1ri

Mzi riC.14.11

M L T D L C.14.12

�i ( zi 1 , ri 1 )

( pi , Api )xi xi 1 � �i pi

ri ri 1 �i Api

zi M 1 ri

(C.14.13)

�i ( zi , ri )

( zi 1 , ri 1 )

pi � 1 zi � �i pi

( zi 1 , ri 1 ) ( zi , ri )

(C.14.14)

Since C is similar to PTPA = M-1A, it has the same condition number. So if M-1 �A-1, then C � I, the

identity matrix. When the conjugate gradient method is applied to the transformed system Cy = d and

then all the equations restated in terms of the original system, some simplification occurs by defining anew vector zi,

So it is necessary to find a matrix M which approximates A, but is faster to invert. There are many

possibilities, but one of the best choices appears to be partial Cholesky factorization.

The sparsity pattern of the original matrix A is preserved in the factored matrix L, i.e., there is no fill-in.

This speeds up the factorization process and minimizes the storage requirements.

The Preconditioned Conjugate Gradient Algorithm can now be outlined:As before, chose x0 and calculate r0 = b - Ax0

Factor A into M = LTDLSolve for z0 from Mz0 = r0

Set search direction p1 = z0

For i = 1, ... N-1;

If (zi, ri) > �, continue in the loop

End of loop



�i ( ri 1 , Api )

( Api , Api )

xi xi 1 � �i pi

ri ri 1 �i Api

zi M 1 ri

(C.15.1)

�i ( Azi , Api )

( Api , Api )

pi � 1 zi � �i pi

(C.15.2)

Notice that the solution of Mzi = ri takes place in each step. Therefore, each step takes considerably

longer than the unconditioned conjugate gradient algorithm. This is more than made up for by thereduction in the number of steps required to reach convergence, typically by a factor of ten.

Section 15: Preconditioned Conjugate Residual Solver

The Preconditioned Conjugate Residual Solver is used when the system matrix is not symmetric. It issimilar to the ICCG method, but a LU decomposition is performed instead of Cholesky. The procedurefollows the following steps:

Chose an initial estimate x0 and calculate r0 = b - Ax0

Factor A into M = LU

Set search direction p1 = r0

For i = 1, ... N-1;

If (ri, ri) > �, continue in the loop

End of loop



grain envelope

Final Grain Size

fg

Fraction of Grain

fs0

1

Concentration

1

2 3

C*C0

Figure C-1 Schematic representation of an equiaxed dendritegrain; region 1 = solid phase; region 2 = interdendritic liquid;region 3 = liquid.

Section 16: Micromodeling

Equiaxed Dendrite Model

This model is also based on instantaneous nucleation, whereby the final grain size is known from thenucleation model. This model is also based on 1--D spherical growth. Following nucleation, the dendritetip growth is controlled by the supersaturation at the dendrite tip. This means that the tip growth is basedon the total undercooling at the tip. As the tip grows, the solid fraction in each grain is not known fromthe tip position. In fact, the fraction solid is less than the fraction of the grain obtained from the tipposition. At each time, the new tip concentration and fraction solid are known from a thermal and solutebalance at the scale of the grain. The tip growth velocity is obtained from the Lipton-Glicksman-Kurzmodel, which simulates the growth of an isolateddendrite tip. The tip continues to grow until it reachesthe end of the grain. At this point, solid fraction is stillless than unity. However, mixing of the solute iscomplete at this stage. Therefore, a Scheil typeequation can be used to calculate solid fraction. Ifthe phase diagram has a terminal reaction, e.g.,eutectic, the remaining liquid gets rapidly transformedinto a solid structure.

Figure C-1 shows an eutectic grain and its soluteconcentration profiles. fs is the fraction solid in thegrain and if the dendrite is compressed to form a solidsphere, then the corresponding radius of the solidwould be Rs. fg is the fraction of grain enveloped bythe dendrite tip. The radius of the graincorresponding to fg is given by Rg. The final grainradius is Rl, which is obtained from the nucleationmodel.

In this figure, it may be noted that there is a boundarylayer of solute ahead of the dendrite tip. It is assumed that mixing of solute in the interdendritic region iscomplete (region 2 in Figure C-1). It is also assumed that the temperature of the grain is uniform andcurvature undercooling is neglected. Also it is considered that the thermal undercooling is negligible. The growth of the dendrite tip is controlled mainly by solute diffusion. Therefore, only solutalundercooling is considered.



Pfs

0

kc � (fs)dfs � c � ( fg fs ) � P1

fg

c ( f, t)df c0 C.16.1

'CpdTdt

'L dfdt

#43%R 3

l Qext # 4%R 2l C.16.2

dTdt

dT �

dt m dc �

dtC.16.3

Ac �2� Bc �

� C 0 C.16.4

r Rg , c c � C.16.5

A solute balance at the scale of the grain is written as:

where, k is the partition coefficient, c*( fs) is the tip concentration as a function of fs, co is the initial soluteconcentration, c( f, t ) is the concentration in the liquid region 3 as a function of fraction of grain and time. The three terms are for solute content in the three regions of Figure C-1.

The following equation describes a thermal balance at the scale of the grain, assuming that thetemperature in the grain is uniform:

where, ' is the density, Cp is the specific heat, L is the gravimetric latent heat of fusion, Qext is theexternal heat flux of the solidifying grain.

The assumption of uniform temperature and interface equilibrium leads to the following equation:

where, T* is the temperature at the dendrite tip and m is the slope of the liquidus line. The incorporationof the thermal balance equation in the solute balance equation leads to the following quadratic equationin the dendrite tip concentration, c*:

where, the coefficients A, B, and C are evaluated at every time step. The coefficients A, B, C involveterms that include total solute content in the solid ( region 1 ) and the total solute content in the liquid(region 3). In order to calculate the total solute content in the liquid region of the grain as well as toobtain the concentration at the end of the grain, the diffusion equation in the liquid region needs to besolved. This is done by assuming that the diffusion is quasi-steady in nature. Then, the diffusionequation is solved analytically with the following boundary condition:



d Rg

dt A � T 2 C.16.6

Solution of the above quadratic equation leads to the evaluation of interface concentration at thedendrite tip at each time step. Once the interface concentration is known, the rate of change of fractionof solid at each time step is obtained from the thermal balance equation as given above. This is used tocalculate the heat source term in the energy balance equation at every time step.

The tip growth velocity is obtained with the Lipton-Glicksman-Kurz model which considers that growth ofthe dendrite tip is controlled by solute diffusion and that thermal undercooling is neglected. This ismostly valid for a situation where the Peclet number is low. The following equation results from thismodel:

where �T is the solutal undercooling at the dendrite tip and A is a parameter that involves solutediffusivity in the liquid, liquidus slope, initial solute concentration, Gibbs-Thompson coefficient and thepartition coefficient.

Since nucleation starts instantaneously with zero degree undercooling, the interface concentration willincrease to drive the dendrite tip growth. The growth of the dendrite tip is rapid in the beginning becausethe driving force i.e., the difference between the interface concentration and concentration at the end ofthe grain, is large. Toward the end of solidification both the interface concentration and theconcentration at the end of grain increase because of solute rejection in liquid, and hence the growth rateis slowed down.

The solute diffusion calculation is continued until the time when the dendrite tip radius becomes equal tothe grain radius. The equiaxed dendritic growth continues until the fraction of solid becomes one oranother terminal reaction takes place. If this reaction is an eutectic reaction, all the remaining liquid getstransformed into an eutectic structure.



�2 M # t 1/3s C.16.7

M

D lnC m

l

C0

m(1 k)(C0 C ml )

C.16.8

The secondary dendrite arm spacing parameter is obtained using the coarsening model of Feurer andWunderlin, which is described through the following equation:

where �2 is secondary dendrite arm spacing, ts is the local solidification time, M is the coarsening rateconstant which can be computed with the following equation:

where = Gibbs-Thompson CoefficientD = Solute Diffusion Coefficient in Liquid PhaseCo= Initial Solute Concentration of the alloym = Liquidus slopek = solute partition coefficient

Clm = final composition of solute in liquid at the end of dendrite solidification

In most cases, Clm is equal to the eutectic composition, Ce. A typical value of M for an Al-7%Si alloy is

8.8. 10-6 m . s-1/3

Coupled Eutectic Growth Models

The Coupled Eutectic Growth Models are divided into two categories:1. Instantaneous Nucleation2. Continuous Nucleation

These models can be applicable to both regular and irregular eutectics. In the case of regular eutectics,growth of both phases of the eutectic structure are non-faceted in nature. For irregular eutectic, thegrowth process of one of the phases is faceted. Growth of the faceting phase requires considerablyhigher entropy of fusion. Examples of faceted growth are graphite growth in stable austenite/graphiteeutectic and Silicon in Al-Si eutectic. The metastable austenite/cementite eutectic is an example ofnon-faceted/non-faceted type eutectic growth.

Growth of both the stable and metastable eutectic are addressed here. Growth of the stable eutecticusually proceeds at a higher temperature. For example, the difference between the stable andmetastable eutectic temperature in cast iron is about 6 (C. This value may, however, be influenced bythe amount of alloying elements present. A higher cooling rate results in the formation of a metastableeutectic.

These models assume bulk heterogeneous nucleation at foreign sites which are already present withinmelt or intentionally added to the melt by inoculation. So these models are valid for the equiaxed regionof castings. The basic theory of heterogeneous nucleation has been described by Turnbull and Fisher. Considering the fact that the initial nucleation site density n0 in the melt will decrease as the nucleation



�n K1 [n0 n(t) ] expK2

T (� T )2C.16.9

Figure C-2 Continuous Distribution of Nucleation Sites used for modeling equiaxedsolidification

proceeds ( i.e., extinction of nucleation sites ), the nucleation rate is given as:

where K1 is proportional to the collision frequency of the atoms of the melt with the nucleation sites of theheterogeneous particles and K2 is described as a function of the interfacial energy balance between thenucleus, the liquid, and the foreign substrates, �(t) is the nucleation density as a function of time. Thedrawback of the above model is that the final grain density does not depend on solidification conditions,which is an experimental fact.

To avert this, the instantaneous nucleation model is modified to take into account the dependance ofcooling rate on the number of nucleation sites or substrates. With an increase in cooling rate orundercooling, the number of substrates increases which explains the existence of more grains in fastercooled regions of a casting.

The continuous nucleation model is based in principle on Oldfield's approach, as modified by Rappaz. The modifications lie in the use of a statistical approach. This model is described in Figure C-2.



Eutectic cellsLiquid

Figure C-3 Schematic representation ofequiaxed eutectic growth model.

dRe

dt µ � T 2 C.16.10

T 1e Te � m( Ce C 1

e ) C.16.11

In continuous nucleation, the process starts at the nucleation temperature and proceeds until the stagewhen the minimum in the cooling curve is attained. The grains whichhave already nucleated grow to some extent by the time the minimumundercooling is reached, giving a Gaussian distribution in size. Byconducting a few experiments, the mean and standard deviation ofthis distribution can easily be determined from simple DTA-typeexperiments using liquid from a given melt. Regardless of thenucleation process, the models assume that the grains are equiaxedand that they grow freely in liquid as spheres until they impinge oneach other. The growth process stops when all the liquid isconsumed. Figure C-3 is a schematic representation of equiaxedgrowth of eutectic grains at some intermediate stage of growth.

The growth of the grains is controlled by thermal undercooling at thesolid/liquid interface. Solutal undercooling is neglected here sincesolute diffusion during eutectic solidification is negligible. Thethermal undercooling is given by the difference between the eutectictemperature and the actual solid/liquid interface temperature. Thebulk temperature at the grain is known from the macromodel. The difference between the eutectictemperature and this temperature gives bulk undercooling. The interfacial undercooling is obtained fromthe bulk undercooling from a heat balance equation This is possible once the final grain size is knownfrom the nucleation law. The growth velocity of eutectic grains is given by the following equation, wheregrowth is assumed to take place by screw dislocation:

where µ is the growth constant. Both the stable and metastable eutectics are assumed to grow accordingto the above equation. During growth, the partition of solute element between the solid and the liquidphase is accounted for. The stable eutectic temperature is computed at each time by considering theactual solute concentration in the liquid, as shown below:

where Te and Ce are the equilibrium eutectic temperature and composition respectively. Te1 and Ce

1 are

the eutectic temperatures and composition respectively at a given time step.



0 fs

0 t (1 fs ) 4 %R 2

e NdRe

dtC.16.12

Graphite

Austenite

Rl

Temperature

Cc

Liquid

Ra

Radius

RC

Ca

Cl

Figure C-4 Schematic representation of an eutecticductile iron grain and associated concentration profilesand phase diagram. equiaxed eutectic growth model.

The rate of change of the fraction of solid is calculated with the Johnson-Mehl approximation, assumingthat the solid/liquid interface is weighted by the factor ( 1 -- fs ) to take into account the impingement ofgrains toward the later part of solidification:

where Re is the radius of eutectic grain and N is the substrate density. When the instantaneousnucleation model is used, N becomes a function of cooling rate. For continuous nucleation, N becomesa function of temperature.

Ductile Iron Eutectic Model

The eutectic growth process in ductile iron is a divorcedgrowth of austenite and graphite, which do not growconcomitantly. At the beginning of the liquid/solidtransformation, graphite nodules nucleate in the liquidand grow in the liquid to a small extent, about 10 µm. The formation of graphite nodules and their limitedgrowth in liquid depletes the melt locally of carbon in thevicinity of the nodules. This facilitates the nucleation ofaustenite around the nodules, forming a shell. Furthergrowth of these nodules is possible by diffusion of carbonfrom the melt through the austenite shell.

Mathematical simulation of this growth begins with aninstantaneous nucleation model that determines the finalgrain size from the local cooling rate at the onset ofsolidification. Second, once the austenite shell is formedaround each nodule, the diffusion equation for carbonthrough the austenitic shell is solved in 1--D sphericalcoordinates. The boundary conditions are known fromthe phase diagram because thermodynamic equilibrium is maintained locally. Conservation of mass andsolute is maintained in each grain. Because of the density variation resulting from the growth ofaustenite and graphite, the expansion/contraction of the grain is taken into account by allowing the finalgrain size to vary. Toward the end of solidification, the grains impinge on each other. This is taken intoconsideration by using the Johnson-Mehl approximation.



'c.43%R 3

c � 'a.43% (R 3

a R 3c ) � 'l .

43% ( R 3

l R 3a ) mav C.16.13

'c.1. 43%R 3

c �

Ra

Rc

'a.c(r, t) 4 % r 2 dr � 'l cl .43% (R 3

l R 3a ) cav C.16.14

Figure C-4 shows a schematic representation of an eutectic ductile iron grain. This is the situation afterthe graphite nodules grow in liquid to a limited extent following nucleation. Using a spherical coordinatesystem, a mass balance is written as:

where'c, 'a, 'l are the densities of graphite, austenite, and liquid respectivelyRc, Ra, Rl are radii of graphite, austenite, and final grain respectivelymav is average mass of the grain

Assuming complete mixing of solute in liquid, the overall solute balance is written as:

Differentiation of the above two equations and use of Ficks' law in spherical coordinates leads to twoequations for graphite and austenite growth rates following some manipulation. This diffusion equation issolved for the austenite shell with the following two boundary conditions:

1. at r = Rc, c(r,t) = cc

2. at r = Ra, c(r,t) = ca

where cc, ca are obtained from the phase diagram for temperature T as shown in Figure C-4. The liquidconcentration at this temperature is given as cl at temperature = T. cc, ca, cl are obtained from phasediagram as shown in Figure C-4.



'l 0.1201 � 12.67.106 T � 9.0.104 w lc � 2.16.103 w l

Si1

C.16.15

'a 0.1193 � 9.7.106 T � 4.0.103 w ac 2.2.104 w a 2

c � 1.3.103 w aSi

1C.16.16

'c 0.4419 � 10.5.106 T 1 C.16.17

w lc wt % of carbon in liquid

w ac wt % of carbon in austenite

w lSi wt % of silicon in liquid

w aSi wt % of silicon in austenite

'av 'l ( 1 fs ) � 's fs C.16.18

's

43%R 3

c 'c �43% (R 3

a R 3c ) 'a

43%R 3

a

C.16.19

0 fs

0t ( 1 fs ) 4 %R 2

a N0 Ra

0tC.16.20

During solidification, the densities of the different phases are computed according to the followingequations:

where densities are given in cgs units and temperature in (K,

The average density of a ductile iron grain is given by:

where

The densities are updated at each time based on the temperature. The rate of change of fraction of solidis obtained with the following equation, which incorporates the Johnson-Mehl approximation for grainimpingement:

The source term in the energy equation is computed using the above equation.



N A(�T )n C.16.21

dNdt

n A ( � T )n 1 dTdt

C.16.22

dRe

dt B ( � T )m C.16.23

Gray/White Iron Eutectic Model

This model is a special case of coupled eutectic growth model and is applicable to cast iron only. In castiron, one may obtain both gray and white iron depending on the melt composition and cooling conditions. Given a controlled melt composition, the most important factor that will determine whether a given regionwill solidify as white or gray is the cooling rate. It has been observed that for a specific melt compositionand solidification condition, there exists a parameter called a critical cooling rate. If a region of a castingsolidifies with a cooling rate higher than the critical cooling rate, then it will be white. The reverse is thecase for gray iron. The white structure is brittle and in most gray iron castings, it is considered to bedeleterious.

This model differs from the Coupled Eutectic Growth Models previously described in that the nucleationis described by a predetermined continuous distribution function. The nucleation rate equations for bothgray and white iron are obtained from the following equation:

where N is the final eutectic cell density. By experiment, it was found that A = 7.12 nuclei/cm3/K2 and n= 2.

Differentiation of the above equation with respect to time leads to the following expression for thenucleation rate:

The expression for growth rates was put forward by Oldfield, Magnin, and Kurz. The growth rateequation follows an expression similar to Oldfield's nucleation rate equation. Using a spherical grainapproximation, the growth rate expression is given by:

For gray iron, as reported by Magnin and Kurz, B is taken to be 38.7e-7 cm/s/K2 and m as 2. Theinterfacial undercooling is �T. For white iron, the value of B is taken from the work by Hillert to be30.0e-6 cm/s/K2. It is apparent that white iron grows at a much faster rate than gray iron, which is alsoan experimental fact. Appropriate expressions for nucleation and growth rates are used in the followingstatistical approach.



�(r) A1 � A2 r � A3 r 2 C.16.24

Figure C-5 Eutectic cell distribution assumed forgray/white iron.

� (R) 0 C.16.25

dndr

r R 0 C.16.26

R

R0

�( r ) dr N C.16.27

Statistical Nucleation Model:

The distribution of nuclei are assumed to be described by a polynomial. The treatment in this sectionfollows recent work by Dantzig and coworkers. The nature of the polynomial is shown in Figure C-5 andexpressed by the following equation:

where �(r) describes the cell density as a function of cell radius, r and A1, A2, A3 are constants to bedetermined from the properties of the distribution.

Figure C-5 shows the distribution.

The three unknown parameters in the above equation areobtained with the following three properties (Figure C-5 ): 1. At the maximum radius, R, the cell density is

zero. 2. The first derivative of the distribution evaluated at

the maximum radius is zero. 3. The area under the shaded area in Figure C-5,

which is the total number of cells in thedistribution, is N.

The following three equations describe these properties mathematically:



fs

R

R0

43% r 3.�(r).dr C.16.28

Figure C-6 Schematic Representation of Eutectoid portionof Fe-C-Si phase diagram.

Since the nuclei are assumed to be spherical, the fraction of solid can be locally expressed as:

After manipulation with the properties, an expression for the fraction of solid is obtained. Differentiationof this expression leads to another expression that involves the nucleation rate and growth rate of nuclei. The nucleation rates and growth rates for gray and white iron eutectic cells are obtained using equationsexpressed earlier. To take into account impingement, the growth rate expressions are modified by theuse of Johnson-Mehl expression. Finally, the source term in the energy equation is obtained from thetime rate of change of fraction of solid.

Ductile Iron Eutectoid Model

This model may be used during the eutectoidtransformation while describing the complete phasetransformation of ductile iron from pouring temperature toroom temperature. Also it may be used when the iron isheated from room temperature to the austenitizingtemperature and then annealed or normalized as part of aheat treatment procedure.

The eutectoid reaction leads to the decomposition ofaustenite into ferrite and graphite for the case of thestable eutectoid and to pearlite for the metastableeutectoid transformation. Usually, the metastableeutectoid temperature is lower than the stable eutectoidtemperature. Slower cooling rates result in more stableeutectoid structure.

Following solidification, the solubility of carbon inaustenite decreases with the drop in temperature until thestable eutectoid temperature, AT is reached (Figure C-6). The rejected carbon migrates toward graphite nodules, which are the carbon sink. This results in carbondepleted regions in austenite around the graphite nodules. This provides favorable sites for ferrites tonucleate, which grow as a shell around graphite nodules. If the complete transformation of austenite isnot achieved when the metastable temperature, A1 in Figure C-6 is reached, pearlite forms and grows incompetition with ferrite.



Growth of Ferrite:

Even though ferrite can form either from the breakdown of pearlite or from the direct decomposition ofaustenite, it is assumed here that ferrite results only from the latter source.

The following assumptions are made for modeling the growth of ferrite:

1. The austenite to ferrite transformation occurs at steady state and is controlled by carbondiffusion.

2. The ferrite grains grow as spherical shells within austenite grains and the number of ferrite grainsis equal to the number of graphite nodules.

3. Thermodynamic equilibrium exists at graphite/ferrite and ferrite/austenite interfaces. These aredefined by equilibrium solvus lines extended below the equilibrium eutectoid temperatures.

4. Diffusion from the ferrite/austenite interface towards austenite is neglected as diffusioncoefficients and concentration gradients in austenite are small compared to those in ferrite.

Graphite (G)

Ferrite (F)

Ra

Radius

RC

CG

Austenite (A)

RF

CA/F

CG/F

CACF/A

Figure C-7 Schematic representation of the ferrite growthmodel.

Figure C-8 Eutectoid region of a binary Fe-C phasediagram.



dRF

dt

' �

'F

D Fc

Rc

RF (RF Rc )C A/F

C G/F

C F/A C A/F

C.16.29

'c43% (RC �dRc )3

R 3c CG 'F

43% (RF � dRF )3

R 3F C A/F C.16.30

dfF

dt (1 fF fP ) 4 %N R 2

F

dRF

dtC.16.31

Solution of the diffusion equation of carbon in ferrite with the flux balance at the ferrite/austeniteinterface leads to the following equation (see Figure C-7):

whereDc

F = the carbon diffusion coefficient in ferrite

RF = the radius of the ferrite grain and graphite noduleRc = the radius of the graphite nodule

CG/F, CF/A, CA/F = carbon concentration in ferrite at the graphite/ferrite interface, carbonconcentration in ferrite at the ferrite/austenite interface, and carbon concentrationin austenite at the ferrite/austenite interface respectively (Figure C-7).

Since the rejected carbon migrates to the graphite nodule, concomitant growth of ferrite and graphiteresults. The following equation derives from mass conservation:

Therefore, knowing the radius of the ferrite grain, the radius of the graphite nodule can be obtained fromthe above equation. Then the rate of change of fraction of ferrite grain is obtained by:

where fF, fP are fractions of ferrite and pearlite, and N is the number of graphite nodules. The aboveequation is used to obtain the source term due to ferrite growth associated with the stable eutectoidtransformation.

Nucleation and Growth of Pearlite:

The nucleation of pearlite usually occurs at austenite grain boundaries. It has been demonstrated thatpearlite colonies grow either as spheres or hemispheres following nucleation. By the movement of highmobility ( i.e., low interface energy ) incoherent interfaces, these colonies can grow edgewise or sidewiseinto the austenite. This means that pearlite grows in competition with ferrite until austenite is completelytransformed.



dNpearl

dt 5.07.106exp

370� Teud

C.16.32

dRpearl

dt 0.0168 exp

94.8� Teud

C.16.33

dRferr

dt

C2 C3

C4 C3

D Fc

R 2F

1RF

1

R 0F

C.16.34

Transformation of austenite into pearlite is usually modeled with an Avrami equation because the studyof nucleation of pearlite is difficult, especially under continuous cooling conditions. Also, pearlite grainsimpinge on each other at an early stage, especially at a relatively high cooling rate. Here, equations fornucleation and growth of pearlite grains are taken from the work of Mehl and Dube:

where the pearlite nucleation density is given in nuclei/mm3/sec and the undercooling is given in (K. Thenucleation process stops once the minimum in the cooling curve is reached. The expression for the timerate of change of fraction of pearlite transformed is given by an expression similar to that for ferrite.

Gray Iron Eutectoid Model

The gray iron eutectoid transformation model is based on the approach used for gray iron eutectic. Herea statistical distribution is assumed. Details of this approach are given above in the explanation for thegray iron eutectic model. Nucleation and growth of ferrite takes place once the temperature drops belowthe stable eutectoid temperature. If the transformation of austenite is not complete when the metastableeutectoid temperature is reached, then nucleation and growth of pearlite takes place.

In this statistical approach, nucleation and growth takes place once the temperature drops below thetransformation temperature. During nucleation, the radii of nuclei are introduced at R0 (Figure C-5). Since the existing nuclei grow, both the cell density and maximum radii, R, increase, while the minimumradius, R0, stays the same. When nucleation ends at the minimum point of the cooling curve, theexisting nuclei keep on growing until the transformed fraction becomes 1. The number of nuclei does notchange from this point on.

An instantaneous nucleation mechanism was used for ferrite. The growth of ferrite grains is controlled bya diffusion mechanism as explained for the growth of the ductile iron eutectoid. The expression forgrowth rate is given below:

The above expression is derived by using a solute flux balance at the ferrite/austenite interface along



c 2 Dl

V� L C.16.35

with the diffusion equation,where

RF0 = the radius of ferrite nucleus

C2 = the carbon content in the middle of ferrite grainC3 = the carbon content at the ferrite/austenite interfaceC4 = the carbon content in austenite

The nucleation and growth rate expressions for pearlite are the same as those for the ductile ironeutectoid model. These equations have been suggested by Mehl and Dube.

All of the above equations are solved as a linear system by the use of Gauss elimination. The rate ofchange of fraction of pearlite and ferrite transformed are used to calculate the source term in themacroscopic energy equation at each time step.

Peritectic Transformation Model

In a peritectic transformation, liquid reacts with an existing solid phase to form a new solid phase. Inconventional models, the new solid is assumed to form at the interface between the parent liquid andsolid phases. Once the new solid phase is formed, further reaction between the parent phases is limitedby the layer of solid formed. Hence the rate of reaction is controlled by the diffusion of solute throughthe shell of the transformed product.

The following discussion is for the Fe-C system. However, it is valid for all other systems undergoing aperitectic transformation, with a few relevant assumptions. It has been suggested by some researchersthat the peritectic transformation may be achieved through a liquid layer in between the parent and theproduct solid phases. This mechanism has been adopted in the present model. For example, in thecase of steel, the austenite phase forms initially at the root of the dendrite arms of the delta phase andgrows along the delta/liquid interface. The speed of this growth is the same as that with which liquidmoves toward the delta phase. The diffusion problem can be simplified as the liquid layer is very thinand the diffusion of carbon in the liquid is very rapid so that the carbon concentration gradient in theliquid is negligible. Here the solute diffusion boundary layer is much greater than the system size i.e.,the following condition holds:

where c = the thickness of the boundary layerDl = the solute diffusivity in liquidV = the speed of growthL = the system size



L � � C.16.36

[ ( fL.CL C �

s, � ) ( fL.Cl f C �

s, ) ] dfs (1 fs ) dCl � s, �

2LdC �

s, � s,

2LdC �

s, C.16.37

fL and f fractions of liquid and delta phases reactingCl the liquid concentration

C �

s, and C �

s, � solute concentrations at the delta/liquid and austenite/liquid interfaces respectivelyL the system sizedCl the change � solute concentration in liquid s, � and s, the solute boundary layer thicknesses in gamma and delta phases

�1 � 1 exp

1�

12

exp

12�

C.16.38

It is assumed that the above condition is maintained for any system undergoing peritectic transformation. The model is based on a Brody-Flemings formulation, with recent modifications suggested by Zou andTseng. For the peritectic transformation given by the reaction,

the following mass balance equation may be written:

where

After some mathematical manipulation, an expression is obtained that relates the solute concentration inliquid with the fraction of solid transformed, involving some parameters such as dimensionlesscoefficients for back diffusion for both delta and austenite phases i.e., � and ��. According to theBrody-Flemings model, the case of � = 0.5 does not correspond to the physical characteristics ofequilibrium solidification. In that case, � should approach infinity. Therefore, a modified back diffusionparameter, �1 has been proposed by Clyne and Kurz. The basis of this calculation is that, in the originalBrody-Flemings treatment for high � values, solute was not conserved in the system. According toClyne and Kurz, the modified back diffusion parameter is defined as:

Differentiation of the equation involving fraction transformed and solute concentration in liquid leads tothe expression for rate of change of fraction of solid assuming thermodynamic equilibrium at thesolid/liquid interface, which is used to calculate the source term in the energy equation.



fv 1 exp [ k(T) t n ] C.16.39

k (T ) exp ( aT 2� bT � c ) C.16.40

Solid Transformation Models

This model is only applicable to the Fe-C system and is used for tracking the fraction transformed for thecases of delta to gamma, gamma to ferrite, and gamma to cementite.

A hypoeutectoid steel may form some delta phase in the beginning while the remaining liquid and somedelta phase undergo a peritectic transformation to form some gamma phase. The remaining delta phasegets transformed to gamma phase. This transformation is addressed by the present model. Delta togamma transformation will be active in the appropriate temperature range when the wt% carbonequivalent value is less than 0.17%.

The delta to gamma phase transformations can be described by the Johnson-Mehl equation, also knownas Avrami equation:

wherefv = the fraction transformedfv = the fraction transformed

k(T) = the rate constant

The rate constant is a function of nucleation and growth rates. It depends on the transformationtemperature and is related to the shape and position of the C curve in a TTT (time-temperature-transformation ) diagram. In most cases, this curve has a parabolic shape and can beapproximated as:

where T represents temperature in K. The parameters a, b, c, n have been determined for each of thesetransformations. Appropriate values are chosen for this transformation from the literature. Differentiation of the equation for fraction transformed with respect to time leads to the expression for thetime rate of change of fraction of delta transformed to gamma.

Again, prior to reaching the eutectoid temperature, some of the austenite phase may transform into alphaphase as part of a pro-eutectoid transformation. If you started with a hypereutectoid composition, thepro-eutectoid transformation will be from austenite ( gamma ) to cementite. Both of these pro-eutectoidtransformations are addressed by the current model. The wt% carbon equivalent determines whether thegamma to ferrite or gamma to cementite transformation will be used. Both of these models require thatthe equiaxed dendrite model be chosen for the initial liquid/solid phase transformation.



R

1�T

Tp

T

V (T ) dT C.16.41

V

D2x

C� C0 )2

(C0 C�)C.16.42

f 2d

R C.16.43

The radius of the transformed ferrite or cementite grain is obtained with the following equation:

where

= cooling rate�T

V(T) = the growth velocity of the ferrite or cementite grain

Assuming steady state thickening, the growth velocity at a given temperature is:

where D = the diffusivity of carbon in austeniteC� = the concentration in austenite at ferrite/austenite interfaceC� = the concentration in ferrite at ferrite/austenite interfaceCo = the original solute concentration in the alloyx = the radius of ferrite

Fraction of austenite transformed into ferrite is given as:

wheref = the fraction transformedd = the austenite grain size

Similar equations have been used for the gamma to cementite transformation, where the growth velocityequation and associated data are obtained from published literature.



(c �

l c �

s ) dfs (1 fs ) dcl C.16.44

c �

l the liquid composition at the solid/liquid interface

c �

s the solid composition at the solid/liquid interfacedcl the change in concentration in liquidfs the fraction of solid

Solute Concentration

ClCoCs

Tm

Tl

T

Ts

Figure C-9 A portion of a binary phase diagram.

Scheil Model

The Scheil model makes the assumptions of complete mixing of solute in liquid and no solute diffusion inthe solid phase. The following equation describes the differential form of the Scheil equation:

where

Consider a portion of a binary phase diagram as shown in Figure C-9.

In Figure C-9, Tl and Ts are the liquidus and solidus temperatures respectively. cl and cs are soluteconcentrations in the liquid and solid phases at some temperature, T. co is the initial solute concentrationin the alloy and Tm is the melting point of the pure solvent.

The change of fraction of solid obtained with the above equation is used for the calculation of the sourceterm in the macroscopic energy equation.



Output of Micromodels

Equiaxed Dendrite Model

This primary dendrite solidification yields the following spatially varying output:

1. DENDRITE RADIUS2. DENDRITE TIP COMPOSITION3. PRIMARY FRACTION OF SOLID4. PRIMARY INT. SOLID FRACTION5. SECONDARY DENDRITE ARM SPACING

The DENDRITE RADIUS provides the current position of the dendrite tip and volume fraction of thedendritic grain as it varies with time. At the end of the primary solidification, this parameter will equal thefinal grain radius as calculated from the instantaneous nucleation law with the prevailing cooling ratevalue. This is true provided a terminal reaction such as an eutectic reaction does not take placebeforehand. Subtraction of the value of the PRIMARY FRACTION OF SOLID at the beginning of theeutectic reaction provides the total amount of the eutectic at a given location. The PRIMARY INT. SOLID FRACTION parameter increases from a small value to unity as the primary solidificationproceeds. It is the ratio of the current volume of the grain as known from the DENDRITE RADIUS andthe final volume of the grain as known from the nucleation law. At the onset of the eutectic reaction,subtraction of the value of the PRIMARY INT. SOLID FRACTION from unity provides the amount of thefraction of the eutectic between the grains. Subtraction of this amount of eutectic between grains fromthe total amount of the eutectic provides the amount of eutectic between dendrite arms. In most cases, itis important to know how much eutectic will form between grains and between dendrite arms.

With the progress of solidification, the DENDRITE TIP COMPOSITION parameter will continuouslychange from the initial to the eutectic composition. A map of this parameter over the entire casting at agiven instant gives an idea about microsegregation, since the concentration of the solid phase forming isproportional to the tip concentration. The information about microsegregation is important for describingnon-equilibrium behavior in castings. This is the cause of interdendritic precipitation of eutectic, even ifthe initial alloy composition is not on eutectic tie line.

The SECONDARY DENDRITE ARM SPACING (SDAS), which is the spacing between the secondaryarms of a dendrite, depends upon the local solidification time. As the SDAS increases, the mechanicalproperties deteriorate. SDAS also determines the spacing of precipitates and/or porosity. TheSecondary Dendrite Arm Spacing is output when either the eutectic transformation model and/or theperitectic transformation model are used.

Coupled Eutectic Growth Model with Instantaneous Nucleation

1. LARGE EUT. GRAIN RADIUS2. EUTECTIC FRACTION OF SOLID3. INTER-LAMELLAR SPACING4. METASTABLE EUT. GRAIN RAD.5. MET. EUTECTIC FR. OF SOLID

The LARGE EUT. GRAIN RADIUS and METASTABLE EUT. GRAIN RAD. parameters provide the



�2 V K C.16.45

V µ ( � T )2 C.16.46

Vt �2t Vt � � t �

2t � � t C.16.47

instantaneous value of the stable and metastable eutectic grain radii, which can be used to control themechanical properties of the cast part. The EUTECTIC FRACTION OF SOLID and MET. EUTECTICFR. OF SOLID parameters give the relative amount of stable and metastable eutectic structure. Forexample, in cast iron the metastable eutectic (white) may be undesirable. The INTER-LAMELLARSPACING parameter determines the fineness of the eutectic. Smaller values of this parameter providebetter mechanical properties. The Jackson-Hunt equation for the eutectic interlamellar spacing is givenwith the following equation:

Where, V is the velocity at the eutectic front. The velocity of the eutectic front can be expressed in thefollowing form:

Here, �T is the interfacial undercooling at the eutectic front. Combining the above two equations, thefollowing equation is written:

The instantaneous value of the inter-lamellar spacing is obtained with the above equation. At the end ofsolidification, an average value of the inter-lamellar spacing is obtained.

Coupled Eutectic Growth Model with Continuous Nucleation

The following parameters are similar to those for the Coupled Eutectic Growth Model with InstantaneousNucleation. The only additional quantity is the EUTECTIC GRAIN RADIUS, which gives the stableeutectic grain density as a function of time over the entire casting. In many cases, a large number of thisparameter will be desirable from the standpoint of mechanical properties.

1. LARGE EUT. GRAIN RADIUS2. EUTECTIC FRACTION OF SOLID3. EUTECTIC GRAIN RADIUS4. INTER LAMELLAR SPACING5. METASTABLE EUT. GRAIN RAD.6. MET. EUTECTIC FR. OF SOLID



Ductile Iron Eutectic ModelThe following parameters are displayed when this particular micromodel is selected.1. AUSTENITE RADIUS2. GRAPHITE RADIUS3. EUTECTIC FRACTION OF SOLID4. EUTECTIC GRAIN RADIUS

The EUTECTIC GRAIN RADIUS parameter gives the final radius of eutectic grains over the entirecasting. This is governed by the function used to describe the dependence of the nodule count on thecooling rate. In ductile iron, each eutectic grain consists of a graphite nodule enveloped in an austeniteshell. The AUSTENITE RADIUS and GRAPHITE RADIUS provide the instantaneous values of thesolidified grain size and nodule size respectively. At the end of solidification, they provide a correctdescription of the final grain size and nodule size. The AUSTENITE RADIUS should in principle coincidewith the final grain size as given by the EUTECTIC GRAIN RADIUS parameter. However, because ofthe grain impingement, AUSTENITE RADIUS may exceed the EUTECTIC GRAIN RADIUS. A map ofthe EUTECTIC FRACTION OF SOLID parameter can be used to determine areas of shrinkage formationin castings. AUSTENITE RADIUS AND GRAPHITE RADIUS can be related to the mechanicalproperties of castings. Density is calculated from the local fraction of graphite, austenite, and liquid, thuscapturing the peculiar contraction and expansion behavior of ductile iron.

Gray/White Iron Eutectic ModelThis model uses a statistical distribution for nucleation. 1. LARGE EUT. GRAIN RADIUS2. SMALL EUT. GRAIN RADIUS3. FRACTION OF SOLID4. EUTECTIC GRAIN RADIUS5. INTER LAMELLAR SPACING6. METASTABLE EUT. GRAIN RAD.7. SMALL MET. EUT. GR. RADIUS8. MET. EUTECTIC FR. OF SOLID9. MET. EUTECTIC GR. DENSITY

The LARGE EUT. GRAIN RADIUS and SMALL EUT. GRAIN RADIUS refer to the maximum andminimum values of the stable (gray) eutectic grain radius as a function of time during eutectic growth. Similarly, METASTABLE EUT. GRAIN RAD. and SMALL MET. EUT. GR. RADIUS parameters arerelevant for the metastable (white) eutectic. Mechanical properties of the cast part are a function of thestable and metastable eutectic grain sizes. FRACTION OF SOLID gives the amount of the gray eutectic,whereas MET. EUTECTIC FR. OF SOLID gives the amount of the white eutectic. In most cases, thegray structure is more desirable as it gives improved tensile strength and ductility. The EUTECTICGRAIN RADIUS parameter gives the gray eutectic grain density and the MET. EUTECTIC GRAINDENSITY gives white eutectic grain density. These two parameters are connected to mechanicalproperties in a similar fashion to the grain radius parameters. The Eutectic Grain Density of Gray andWhite Iron are used to describe the number of grains per unit volume at a given location of a casting. This can be correlated with the mechanical properties of the cast part. The INTER LAMELLARSPACING parameter calculates the spacing of the gray eutectic which is explained under CoupledEutectic Growth Model with Instantaneous Nucleation.

Ductile Iron Eutectoid Model



As explained earlier, the stable eutectoid growth refers to the decomposition of austenite into ferrite andgraphite and the metastable eutectoid growth refers to the decomposition of austenite into pearlite, whichis a coupled growth of ferrite and cementite.

1. LARGE FERRITE GR. RADIUS2. FRACTION OF FERRITE3. FRACTION OF PEARLITE4. LARGE PEARLITE GR. RADIUS5. LOCAL PEARLITE GRAIN DENSITY

The properties of the iron depend strongly on the relative amounts of ferrite and pearlite in the matrix. As the pearlite content increases, tensile and yield strengths also increase, but at the cost of ductility. Ferrite content controls fracture toughness and dynamic properties of iron. The amount of ferriteincreases as the nodule count of the iron increases. The FRACTION OF FERRITE and FRACTION OFPEARLITE give the relative amount of stable and metastable eutectoid structures. The pearlite/ferriteratio can be related to tensile strength through its effect on matrix microhardness. The LARGEFERRITE GR. RADIUS and LARGE PEARLITE GR. RADIUS provide the stable and metastableeutectoid grain radii as a function of time. LARGE PEARLITE GR. RADIUS can provide a qualitativeestimate of interlamellar spacing, which can be related to mechanical properties. Also, LOCALPEARLITE GRAIN DENSITY can be used to estimate the mechanical properties. Usually, a finerpearlite grain size is associated with a finer interlamellar spacing with better mechanical properties.

Gray Iron Eutectoid Model

This model uses a statistical distribution of nuclei as explained for Eutectic Gray/White Iron model.

1. LARGE FERRITE GR. RADIUS2. SMALL FERRITE GR. RADIUS3. LARGE PEARLITE GR. RADIUS4. SMALL PEARLITE GR. RADIUS5. FRACTION OF FERRITE6. FRACTION OF PEARLITE7. LOCAL PEARLITE GRAIN DENSITY

The above parameters reflect the same kind of behavior as they do in the case of the Ductile IronEutectoid Model. The only difference is that stable and metastable eutectoid grain sizes are provided asa range extending from a minimum value to a maximum value.



Peritectic Transformation Model

1. PERITECTIC FR. OF SOLID2. LIQUID CONCENTRATION

Usually, peritectic growth is limited by the formation of the solid transformed product at the reactingliquid/solid phase boundary. The PERITECTIC FR. OF SOLID parameter gives the volume fraction ofsolid resulting from this reaction. It is important to know the amount of the phase formed through thisreaction, as it usually forms as a surface layer on the primary dendritic solid phase. Segregation ofsolute is a problem during this reaction, as diffusion is limited in the transformed phase. LIQUIDCONCENTRATION provides a measure of this effect as a function of time. Segregation is a problemunless the cast part undergoes significant plastic deformation and heat treatment later on.

Solid Transformation Models

1. FRACTION TRANSFORMED2. FRAC. OF PROEUTECTOID PHASE

The FRACTION TRANSFORMED parameter refers to the delta to gamma phase transformation. TheFRAC. OF PROEUTECTOID PHASE refers to the fraction of proeutectoid ferrite or cementite formedfrom the austenite phase as a function of time. The carbon equivalent value controls which type of theproeutectoid phase (ferrite or cementite) will form.

Scheil Model

The Scheil Model is usually used to model the primary dendrite growth.

1. PRIMARY FRACTION OF SOLID2. LIQUID CONCENTRATION

The PRIMARY FRACTION OF SOLID parameter provides the time-dependent evolution of the primarysolid fraction. The LIQUID CONCENTRATION parameter gives the progressive concentration in theliquid at the solid/liquid interface of the solidifying grain. This is also the concentration in the entire liquidphase of the grain since the Scheil model assumes complete solute mixing in liquid. Since the effect ofthe undercooling at the tip is not taken into consideration, this model will not predict any variation inprimary solid fraction as a function of cooling rate as one observes in an equiaxed dendrite model.



Figure C-10

�2ex V

Kr

KcC.16.48

Interlamellar spacing

The interlamellar spacing that is addressed here is basedon the Jackson-Hunt model of eutectic growth. It isassumed that the interlamellar spacing follows theextremum criterion condition, which means that suchinterlamellar spacing will be chosen by the system so asto minimize the undercooling at the eutectic front. Inother words, it is assumed that the growth valocity ismaximized for the extremum condition. It may bementioned here that the Jackson-Hunt theory is validunder steady state growth conditions. In castings, thegrowth process is unsteady except during the eutecticplateau of the cooling curve. The growth process duringeutectic arrest is close to steady state growth. Therefore,while viewing the contours of this parameter over thecasting, you should be in the steady state growth range. Toward the end of eutectic solidification, thegrowth rate is rapidly increased. Therefore, the interlamellar spacing calculated at that time may not berepresentative of the actual spacing.

The expression for the Jackson-Hunt theory of eutectic growth is given by the following equation:

where�ex = the interlamellar spacing based on the extremum conditionV = the growth velocity of the eutectic front



Kc m C1 P1

f (1 f ) DC.16.49

Kr 2m� sin(��)

fm�

�

� sin(��)

(1 f ) m�

C.16.50

m

m� m�

m� � m� C.16.51

P1 M 1

n 3 %3sin 2 (n % f) C.16.52

�ex (Kr / Kc)

VC.16.53

The expressions for the parameters Kr and Kc are obtained from the following, assuming that the eutecticstructure is composed of � and � phases:

and

where

where

m� and m� = absolute liquidus slopes in � and � side of the phase diagram

� and � = Gibbs-Thompson coefficients associated with and phases respectively f = the volume fraction of the � phase

C1 = the difference in composition between the ends of the eutectic tie line D = the diffusion coefficient in liquid

�� and �� = the angles are the angles subtended by the tangents of � and � interfaces with theline OY at the intersection of � and � interfaces (see Figure C-10).

The equation of interlamellar spacing is rewritten as:



dQL

dt 'VCp

dTdt

hA( T To ) (C.17.1)

The Jackson-Hunt Parameter here refers to the value of Kr/Kc. Typical experimental values for thisparameter for different systems are listed below:

Eutectic Systems K r/Kc(mm3s-1)

Ag-Pb 1.2. 10-7

Ag3Sn-Sn 2.8.10-7

Al-Al2Cu 1.2. 10-7--1.4. 10-7 (function of C0)

Al-Si 5.8. 10-7--3.1. 10-6 (function of G)

Al-Zn 6.4. 10-8

Bi-Zn 6.9. 10-8

Cd-Pb 2.1. 10-8

Cd-Sn 7.2. 10-8

Cd-Zn 2.8. 10-8

Fe-C 5.6. 10-6

Pb-Sn 2.8. 10-8--3.3. 10-8

Sn-Zn 6.9. 10-8

Section 17: Cooling Curve Analysis

If the internal thermal gradients in a sample are negligible (i.e., if the temperature in the sample isuniform), then the following heat balance equation may be written for the solidifying sample-moldsystem:

Heat transferred to m old = Heat generated by phase transformat ion --- Heat lost by metal

Mathematically, this is expressed with the following equation:

whereQL = latent heat of phase transformation' = density of metal

Cp = Specific heat of metal T = metal temperature t = timeh = heat transfer coefficientA = surface areaV = volume of sample

To = ambient temperature



dTdt cc

dQL

dt hA( T T0 ) ( 'VCp ) (C.17.2)

dTdt zc

hA(T T0 ) ( 'VCp ) (C.17.3)

dQL

dt 'VCp

dTdt cc

dTdt zc

(C.17.4)

QL 'VCp

tf

o

dTdt cc

dTdt zc

dt (C.17.5)

The above equation is rearranged as:

This equation is valid for the cooling curve. If there is no phase transformation during cooling of metal,

then is zero. Therefore, the following equation is written:dQL

dT

Here, the subscript zc represents the zero curve. Taking the difference between these two equations, the

following equation is written:

Integration of this equation yields:

Here, tf is the solidification time. Therefore, the latent heat for phase transformation is obtained as L =QL/'V.

PREFIXD.DAT FILE FORMAT

APPENDICES, PAGE D - 1

APPENDIX D

prefix d.dat FILE FORMAT

The formatted file containing the description of the problem is the prefixd.dat file. This file is normally created by PreCAST and

processed by DataCAST to check for errors in the model and then create the binary simulation file.

It is possible to create the prefixd.dat file manually if the problem is small. However, it is much more likely that you would want to make

minor changes in the problem setup, such as changing one heat transfer coefficient, by editing the prefixd.dat file.

This appendix provides a description of the records and record formats in this file. Each record of the prefixd.dat file is identified by the

two labels LA and LB. These two numbers must be in 2I2 format. If there are any units in the record, they must be in the format given.

Everything else can be in free format.

( 1, 0 ) Data Set - Title statements

Input: LA, LB, TITLE

Format: 2I2, A80

Content: LA = 1

LB = 0

TITLE = Arbitrary line of information for run documentation

Note: Up to three records of this type may be included.

( 1, 1 ) Data Set - Number of nodes and elements

Input: LA, LB, NTNOD, NTEL

Format: 2I2, 1X, 2I10

Content: LA = 1

LB = 1

NTNOD = Total number of nodes

NTEL = Total number of elements

( 2, 0 ) Data Set - Control parameters

Input: LA, LB, THERMAL, FREE_SURFACE, TWO_D


Content: LA = 2

LB = 0

THERMAL = 0 for no thermal solution ( flow only )

= 1 for thermal solution

FREE_SURFACE = 0 for no free surface flow

= 1 for free surface flow ( filling transients )

TWO_D = 0 for 3D geometry

= 1 for 2D Cartesion geometry

= 2 for 2D cylindrical geometry


PAGE D - 2 PROCAST USER’S MANUAL

(3, 0 ) Data Set - Solid element information

Input: LA, LB, IEL, ITYPE, MINDEX, NODE1, ... NODE10

Format: 2I2, 1X, 3I5, 10I7

Content: LA = 3

LB = 0

IEL = Element number

ITYPE = 1 for 8-node brick element

= 2 for 4-node tetrahedral element

= 3 for 6-node wedge element

= 6 for 4-node quadrilateral element

= 7 for 3-node triangular element

= 9 for 2-node bar element

= 10 for 10-node tetrahedral element

N = Material ID number, points to Data Set ( 3, 1 )

NODE1, = Connectivity data

...NODE*

( 3, 1 ) Data Set - Solid element additional information

Input: LA, LB, U1, N, MTYPE, FLUID, FILLED, VINDEX, THETA, TIC, UPDATE, MOLD, STRESS

Format: 2I2, 1X, I1, 4X, 5I3, 2E15.0, 3I5

Content: LA = 3

LB = 1

U1 = Units for initial condition temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

N = Material ID number

MTYPE = Material number in Data Set ( 5, 0 )

FLUID = 0 this material does not flow

= 1 normal flow material

= 2 filter material

= 3 foam material

FILLED = 0 if elements with this index are initially empty

= 1 if elements with this index are initially filled

VINDEX = Pointer to Data Set ( 6, 5 ) for moving solid elements

THETA = Implicit-explicit time stepping parameter

TIC = Temperature initial condition for elements with this index

UPDATE = Frequency at which to reintegrate the element matrices for this ID

MOLD = 0 if this ID does not represent a mold

= 1 if this ID represents a mold

This is only used when running multiple cycles with the parameters TCYCLE and

NCYCLE..

STRESS = 0 no stress calculation for this material

= 1 linear elastic material

= 2 plastic, linear hardening material

= 3 plastic, power law hardening material

= 4 viscoplastic 1, linear hardening material

= 5 viscoplastic 1, power law hardening material

= 6 viscoplastic 2, linear hardening material

= 7 viscoplastic 2, power law hardening material

Note: The FLUID parameter should be 0 for 1D elements



( 3, 2 ) Data Set - 1D Conduction element information

Input: LA, LB, U1, IEL, INDEX, NODE1, NODE2, AREA

Format: 2I2, 1X, I1, 4X, 2I5, 2I7, E15.0

Content: LA = 3

LB = 2

U1 = Units for the cross-sectional area

= 1 for meters**2

= 2 for centimeters**2

= 3 for millimeters**2

= 4 for feet**2

= 5 for inches**2


INDEX = Pointer to Data Set ( 3, 1 )


NODE2

AREA = Cross-sectional area

( 3, 3 ) Data Set - 1D Interface element information

Input: LA, LB, U1, IEL, INDEX, NODE1, NODE2, AREA

Format: 2I2, 1X, I1, 4X, 2I5, 2I7, E15.0

Content: LA = 3

LB = 3

U1 = Units for the cross-sectional area

= 1 for meters**2



= 4 for feet**2

= 5 for inches**2




NODE2

AREA = Cross-sectional area

( 4, 0 ) Data Set - Node coordinates

Input: LA, LB, U1, NODE, X, Y, Z

Format: 2I2, 1X, I1, 4X, I5, 3E15.0

Content: LA = 4

LB = 0

U1 = Units of the coordinates

= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

NODE = Node number

X,Y,Z = Cartesian coordinates of NODE



( 4, 1 ) Data Set - Enclosure node coordinates

Input: LA, LB, U1, NODE, X, Y, Z

Format: 2I2, 1X, I1, 4X, I5, 3E15.0

Content: LA = 4

LB = 1


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

NODE = Enclosure node number

X,Y,Z = Cartesian coordinates of NODE

( 4, 2 ) Data Set - Radial symmetry information

Input: LA, LB, U1, NSS, NAXIS, X, Y, Z

Format: 2I2, 1X, I1, 4X, 2I5, 3E15.0

Content: LA = 4

LB = 2


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

NSS = Number of symmetric structures ( default = 1 )

NAXIS = 1 for first point defining the axis of symmetry

= 2 for second point defining the axis of symmetry

X,Y,Z = Cartesian coordinates of NAXIS

Note: Two records of this type are required if the radial symmetry option is being used.

( 4, 3 ) Data Set - Mirror symmetry information

Input: LA, LB, U1, NPLANE, X, Y, Z

Format: 2I2, 1X, I1, 4X, I5, 3E15.0

Content: LA = 4

LB = 3


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

NPLANE = 1 for first point defining plane of symmetry

= 2 for second point defining plane of symmetry

= 3 for third point defining plane of symmetry

X,Y,Z = Cartesian coordinates of NPLANE

Note: Three records of this type are required if the mirror symmetry option is being used



( 4, 4 ) Data Set - Gravitational acceleration vector

Input: LA, LB, U1, AX, AY, AZ

Format: 2I2, 1X, I1, 4X, I5, 3E15.0

Content: LA = 4

LB = 4

U1 = Units for acceleration

= 1 for m / sec**2

= 2 for cm / sec**2

= 3 for mm / sec**2

= 4 for ft / sec**2

= 5 for in / sec**2

AX = X component of gravity

AY = Y component of gravity

AZ = Z component of gravity

( 4, 5 ) Data Set - Gravitational vector rotation

Input: LA, LB, U1, TIME, X1, Y1, Z1, X2, Y2, Z2

Format: 2I2, 1X, I1, 4X, I5, 6E10.0

Content: LA = 4

LB = 5


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

TIME = Time function number

X1,Y1,Z1 = Coordinates for first point of rotation axis

X2,Y2,Z2 = Coordinates for second point of rotation axis

( 4, 6 ) Data Set - Rotation data for Periodic Boundary

Input: LA, LB, U1, N, NAXIS, THETA, X, Y, Z

Format: 2I2, 1X, I1, 4X,2I5, 4E15.0

Content: LA = 4

LB = 6


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

N = Periodic data set number

NAXIS = 1 for first point defining the axis of rotation

= 2 for second point defining the axis of rotation

THETA = Angle of rotation


Note: Two records of this type are required if the periodic boundary involves rotation



( 4, 7 ) Data Set - Translation data for Periodic Boundary

Input: LA, LB, U1, N, DX, DY, DZ

Format: 2I2, 1X, I1, 4X, I5, 3E15.0

Content: LA = 4

LB = 7


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

N = Periodic data set number

DX = Translation in X direction

DY = Translation in Y direction

DZ = Translation in Z direction

( 4, 8 ) Data Set - Centrifugal data

Input: LA, LB, U1, U2, NAXIS, TIME, OMEGA, X, Y, Z

Format: 2I2, 1X, 2I1, 3X, 2I5, 4E15.0

Content: LA = 4

LB = 8


= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

U2 = Units for angular velocity

= 1 for radians / second

= 2 for radians / minute

NAXIS = 1 for first point defining the axis of rotation

= 2 for second point defining the axis of rotation

TIME = Time function number for angular velocity

OMEGA = Constant angular velocity


Note: Two records of this type are required if the centrifugal option is being used.

( 5, 0 ) Data Set - Material properties

Input: LA, LB, INDEX, NAME, IENTH

Format: 2I2, 1X, A30, I5

Content: LA = 5

LB = 0

INDEX = Corresponds to MTYPE in Data Set ( 3, 1 )

NAME = Material name

IENTH = Enthalpy curve index, corresponds to set ( 5, 5 )



( 5, 1 ) Data Set - Density Information

Input: LA, LB, U1, MAT, ITEMP, RHO

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 1

U1 = Units for density

= 1 for kg / m**3

= 2 for g / cm**3

= 3 for g / mm**3

= 4 for lb / ft**3

= 5 for lb / in**3

MAT = Material number

ITEMP = Temperature function index for RHO

RHO = Baseline or constant density

( 5, 2 ) Data Set - Specific Heat / Enthalpy Information

Input: LA, LB, U1, MAT, ITEMP, CP

Format: 2I2, 1X, I1, 4X, 3I5, E15.0

Content: LA = 5

LB = 2

U1 = Units for specific heat

= 1 for kJ / kg / K

= 2 for cal / g / C

= 3 for Btu / lb / F


ITEMP = Temperature function index for CP

CP = Constant specific heat

( 5, 3 ) Data Set - Conductivity Information

Input: LA, LB, U1, MAT, ITEMP, COND, ANISO

Format: 2I2, 1X, I1, 4X, 2I5, E15.0, E15.0

Content: LA = 5

LB = 3

U1 = Units for thermal conductivity

= 1 for W / m / K

= 2 for cal / cm / C / sec

= 3 for cal / mm / C / sec

= 4 for Btu / ft / F / sec

= 5 for Btu / in / F / sec

= 6 for cal / cm / C / min

= 7 for Btu / ft / F / min

= 8 for Btu / in / F / min


ITEMP = Temperature function index for COND

COND = Baseline or constant conductivity

ANISO = anisotropic multiplier which is applied in the t parametric direction for 8 noded brick

elements and 6 noded wedge elements. In the case of a 4 noded quadralaterial

element, the anisotropic multiplier is applied in the s parametric direction.

Note: The ANISO parameter is optional.



( 5, 4 ) Data Set - Viscosity Information

Input: LA, LB, U1, MAT, ITEMP, VIS

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 4

U1 = Units for viscosity

= 1 for Pascal - sec

= 2 for N - sec / m**2

= 3 for centpoise

= 4 for poise

= 5 for lb / sec / ft

= 6 for lb / min / ft

= 7 for lb / hr / ft


ITEMP = Temperature function index for VIS

VIS = Baseline or constant viscosity for newtonian flow

( 5, 5 ) Data Set - Enthalpy curves

Input: LA, LB, U1, U2, CURVE, POINT, TEMP, VALUE

Format: 2I2, 1X, 2I1, 3X, 2I5, 2E15.0

Content: LA = 5

LB = 5

U1 = Units for temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

U2 = Units for enthalpy

= 1 for kJ / kg

= 2 for cal / g

= 3 Btu / lb

CURVE = Corresponds to IENTH in Data Set ( 5, 0 )

POINT = Number of point on the curve

TEMP = Temperature of point

VALUE = Enthalpy value of point

( 5, 6 ) Data Set - Fraction Solid and Latent Heat

Input: LA, LB, U1, MAT, ITEMP, LHEAT

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 6

U1 = Units for latent heat

= 1 for kJ / kg

= 2 for cal / g

= 3 Btu / lb


ITEMP = Temperature function index for fraction solid

LHEAT = Latent heat



( 5, 7 ) Data Set - Liquidus and Solidus Temperatures

Input: LA, LB, U1, U2, MAT, LIQUID, SOLID

Format: 2I2, 1X, I1, 4X, I5, 2E15.0

Content: LA = 5

LB = 7

U1,U2 = Units for temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine


LIQUID = Liquidus temperature

SOLID = Solidus temperature

( 5, 8 ) Data Set - Mold Permeability

Input: LA, LB, U1, MAT, PERM

Format: 2I2, 1X, I1, 4X, I5, E15.0

Content: LA = 5

LB = 8

U1 = Units for permeability

= 1 for meters**2



= 4 for feet**2

= 5 for inches**2

MAT = Material number ( points to 5 0 card )

PERM = Permeability

( 5, 9 ) Data Set - Surface Tension Information

Input: LA, LB, U1, MAT, ITEMP, ST

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 9

U1 = Units for surface tension

= 1 for N / m

= 2 for dyne / cm

= 3 for lb / ft

= 4 for lb / in

MAT = Material number ( points to 5 0 card )

ITEMP = Temperature function index for ST

ST = Baseline or constant surface tension



( 5, 10 ) Data Set - Transformation Temperature

Input: LA, LB, U1, INDEX, ICOOL, TT

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 10

U1 = Units for transformation temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

INDEX = Reference index for Data Sets ( 5, 16 ) to ( 5, 24 )

ICOOL = Cooling rate function index

TT = Constant transformation temperature

( 5, 11 ) Data Set - Partition Coefficient

Input: LA, LB, INDEX, ITEMP, PC

Format: 2I2, 1X, 5X, 2I5, E15.0

Content: LA = 5

LB = 11


ITEMP = Temperature function index

PC = Baseline or constant partition coefficient

( 5, 12 ) Data Set - Solute Diffusivity

Input: LA, LB, U1, INDEX, ITEMP, DIFF

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 12

U1 = Units for diffusivity

= 1 for m**2 / sec

= 2 for cm**2 / sec

= 3 for mm**2 / sec

= 4 for ft**2 / sec

= 5 for in**2 / sec

= 6 for m**2 / min

= 7 for cm**2 / min

= 8 for mm**2 / min

= 9 for ft**2 / min

= 10 for in**2 / min


ITEMP = Temperature function index

DIFF = Baseline or constant solute diffusivity



( 5, 13 ) Data Set - Liquidus Slope

Input: LA, LB, U1, INDEX, ICONC, LS

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 13

U1 = Units for liquidus slope

= 1 for K / wt%

= 2 for C / wt%

= 3 for F / wt%

= 4 for R / wt%


ICONC = Concentration function index

LS = Baseline or constant liquidus slope

( 5, 14 ) Data Set - Substrate Density, Nodule Count

Input: LA, LB, U1, INDEX, IFUNC

Format: 2I2, 1X, I1, 4X, 2I5

Content: LA = 5

LB = 14

U1 = Units for substrate density

= 1 for 1 / m**3

= 2 for 1 / cm**3

= 3 for 1 / mm**3

= 4 for 1 / ft**3

= 5 for 1 / in**3


IFUNC = Cooling rate function index if a positive number, for instantaneous nucleation

= Temperature function index if a negative number, for continuous nucleation

( 5, 15 ) Data Set - Lamellar Spacing

Input: LA, LB, U1, INDEX, ICOOL

Format: 2I2, 1X, I1, 4X, 2I5

Content: LA = 5

LB = 15

U1 = Units for lamellar spacing

= 1 for m

= 2 for cm

= 3 for mm

= 4 for ft

= 5 for in


ICOOL = Cooling rate function index



( 5, 16 ) Data Set - Equiaxed Dendrite Micromodel

Input: LA, LB, U1, MAT, I1, I2, I3, I4, I5, GT, C0

Format: 2I2, 1X, I1, 4X, 6I5, 2E15.0

Content: LA = 5

LB = 16

U1 = Units for Gibbs-Thompson coefficient

= 1 for m * K

= 2 for cm * K

= 3 for mm * K

= 4 for ft * F

= 5 for in * F


I1 = Index to Data Set ( 5, 10 )





GT = Gibbs-Thompson coefficient

C0 = Initial alloy composition

( 5, 17 ) Data Set - Coupled/Metastable Eutectic Growth Micromodel Instantaneous or Continuous Nucleation

Input: LA, LB, U1, U2, U3, MAT, I1, I2, I3, I4, GC, MGC, SMP, CCR, EC

Format: 2I2, 1X, 3I1, 2X, 5I5, 5E15.0

Content: LA = 5

LB = 17

U1 = Units for growth constants

= 1 for m / sec / K**2

= 2 for cm / sec / K**2

= 3 for mm / sec / K**2

= 4 for ft / sec / F**2

= 5 for in / sec / F**2

= 6 for m / min / K**2

= 7 for cm / min / K**2

= 8 for mm / min / K**2

= 9 for ft / min / F**2

= 10 for in / min / F**2

U2 = Units of temperature for solvent melting point

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

U3 = Units for critical cooling rate for transition

= 1 for K / sec

= 2 for C / sec

= 3 for F / sec

= 4 for R / sec

= 5 for K / min

= 6 for C / min

= 7 for F / min

= 8 for R / min






GC = Stable growth constant

MGC = Metastable growth constant

SMP = Solvent melting point

CCR = Critical cooling rate for transition



EC = Eutectic composition

( 5, 18 ) Data Set - Eutectic Ductile Iron Micromodel

Input: LA, LB, MAT, I1, I2

Format: 2I2, 1X, 5X, 3I5

Content: LA = 5

LB = 18




( 5, 19 ) Data Set - Eutectoid Ductile Iron Micromodel

Input: LA, LB, MAT, I1, I2


Content: LA = 5

LB = 19




( 5, 20 ) Data Set - Eutectic Grey/White Iron Micromodel

Input: LA, LB, U1, MAT, I1, CCR

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 20

U1 = Units for critical cooling rate for transition

= 1 for K / sec

= 2 for C / sec

= 3 for F / sec

= 4 for R / sec

= 5 for K / min

= 6 for C / min

= 7 for F / min

= 8 for R / min



CCR = Critical cooling rate for grey to white transition

( 5, 21 ) Data Set - Eutectoid Grey Iron Micromodel

Input: LA, LB, MAT, I1


Content: LA = 5

LB = 21





( 5, 22 ) Data Set - Peritectic Transformation Micromodel

Input: LA, LB, U1, MAT, I1, I2, I3, I4, I5, I6, I7, GT, C0, EC, RFS

Format: 2I2, 1X, I1, 4X, 8I5, 4E15.0

Content: LA = 5

LB = 22

U1 = Units for Gibbs-Thompson coefficient

= 1 for m * K

= 2 for cm * K

= 3 for mm * K

= 4 for ft * F

= 5 for in * F



I2 = Index to Data Set ( 5, 11 ) for solid forming partition coefficient

I3 = Index to Data Set ( 5, 11 ) for solid reacting partition coefficient

I4 = Index to Data Set ( 5, 12 ) for liquid diffusivity

I5 = Index to Data Set ( 5, 12 ) for solid forming diffusivity

I6 = Index to Data Set ( 5, 12 ) for solid reacting diffusivity


GT = Gibbs-Thompson coefficient

C0 = Alloy composition

EC = Eutectic composition

RFS = Reacting solid fraction

( 5, 23 ) Data Set - Solid State Transformation Micromodels

Input: LA, LB, MAT, CO

Format: 2I2, 1X, 5X, I5, E15.0

Content: LA = 5

LB = 23


CO = Alloy composition

( 5, 24 ) Data Set - Scheil Micromodel

Input: LA, LB, U1, U2, MAT, I1, I2, I3, FT, SMP, C0

Format: 2I2, 1X, 2I1, 3X, 4I5, 3E15.0

Content: LA = 5

LB = 24

U1 = Units for final temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

U2 = Units of temperature for solvent melting point

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine





FT = Final temperature

SMP = Solvent melting point

C0 = Alloy composition

( 5, 40 ) Data Set - Carreau-Yasuda Non-Newtonian Viscosity

Input: LA, LB, U1, U2, U3, MAT, ITEM0, ITEMI, ITEML, ITEMP, ITEMY, VIS0, VISI, PHASE, POWER,

YASUDA



Format: 2I2, 1X, 3I1, 3X, 6I5, 5E15.0

Content: LA = 5

LB = 40

U1 = Units for viscosity at zero shear rate


= 2 for N - sec / m**2

= 3 for centpoise

= 4 for poise




U2 = Units for viscosity at infinite shear rate


= 2 for N - sec / m**2

= 3 for centpoise

= 4 for poise




U3 = Units for time

= 1 for sec

= 2 for min


ITEM0 = Temperature function index for VIS0

ITEMI = Temperature function index for VISI

ITEML = Temperature function index for PHASE

ITEMP = Temperature function index for POWER

ITEMY = Temperature function index for YASUDA

VIS0 = Zero shear rate viscosity

VISI = Infinite shear rate viscosity

PHASE = Phase shift coefficient

POWER = Power law coefficient

YASUDA = Yasuda coefficient

( 5, 41 ) Data Set - Filter data

Input: LA, LB, U1, U2, MAT, ITIME, ITEMP, VOIDF, SAREA, HTC

Format: 2I2, 1X, 2I1, 3X, 3I5, 3E15.0

Content: LA = 5

LB = 41

U1 = Units for specific surface area (area/volume)

= 1 for 1 / meters

= 2 for 1 / centimeters

= 3 for 1 / millimeters

= 4 for 1 / feet

= 5 for 1 / inches

U2 = Units for fluid-filter heat transfer coefficient

= 1 for W / m**2 / K

= 2 for cal / cm**2 / C / sec

= 3 for cal / mm**2 / C / sec

= 4 for Btu / ft**2 / F / sec

= 5 for Btu / in**2 / F / sec

= 6 for cal / cm**2 / C / min

= 7 for Btu / ft**2 / F / min

= 8 for Btu / in**2 / F / min


ITIME = Time function index for HTC

ITEMP = Temperature function index for HTC

VOIDF = Void fraction of the filter



SAREA = specific surface area of the filter

HTC = Fluid-filter interfacial heat transfer coefficient

( 5, 50 ) Data Set - Magnetic permeability data

Input: LA, LB, U1, MAT, ITEMP, MAGP

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 50

U1 = Units for magnetic permeability

= 1 for Henry / meter

= 2 for Henry / centimeter

= 3 for Henry / millimeter

= 4 for Henry / feet

= 5 for Henry / inch


ITEMP = Temperature function index for MAGP

MAGP = Baseline or constant magnetic permeability

( 5, 51 ) Data Set - Electrical conductivity data

Input: LA, LB, U1, MAT, ITEMP, ECON

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 51

U1 = Units for electrical conductivity

= 1 for 1 / ( ohm-meter )

= 2 for 1 / ( ohm-centimeter )

= 3 for 1 / ( ohm-millimeter )

= 4 for 1 / ( ohm-feet )

= 5 for 1 / ( ohm-inch )


ITEMP = Temperature function index for ECON

ECON = Baseline or constant electrical conductivity



( 5, 60 ) Data Set - Elastic Modulus

Input: LA, LB, U1, MID, ITEMP, ELAST

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 60

U1 = Units for elastic modulus

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar

= 6 for dyne / cm**2

= 7 for atm

= 8 for psia

= 9 for lb / ft**2

MID = Material id number

ITEMP = Temperature function index for ELAST

ELAST = Baseline or constant elastic modulus

( 5, 61 ) Data Set - Poisson ratio

Input: LA, LB, MID, ITEMP, POISR

Format: 2I2, 1X, 4X, 2I5, E15.0

Content: LA = 5

LB = 61


ITEMP = Temperature function index for POISR

POISR = Baseline or constant poisson ratio

( 5, 62 ) Data Set - Thermal expansion coefficient

Input: LA, LB, U1, MID, ITEMP, THEXP

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 62

U1 = Units for thermal expansion coefficient

= 1 for 1 / Kelvin

= 2 for 1 / Celsius

= 3 for 1 / Fahrenheit

= 4 for 1 / Rakine


ITEMP = Temperature function index for THEXP

THEXP = Baseline or constant thermal expansion coeffient



( 5, 63 ) Data Set - Yield stress

Input: LA, LB, U1, MID, ITEMP, YIELD

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 63

U1 = Units for yield stress

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2


ITEMP = Temperature function index for YIELD

YIELD = Baseline or constant yield stress

( 5, 64 ) Data Set - Hardening Parameter

Input: LA, LB, U1, MID, ITEMP, HARD

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 64

U1 = Units for hardening

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2


ITEMP = Temperature function index for HARD

HARD = Baseline or constant hardening

( 5, 65 ) Data Set - Hardening exponent

Input: LA, LB, MID, ITEMP, HARDE

Format: 2I2, 1X, 4X, 2I5, E15.0

Content: LA = 5

LB = 65


ITEMP = Temperature function index for HARDE

HARDE = Baseline or constant hardening exponent



( 5, 66 ) Data Set - Visco power coefficient

Input: LA, LB, MID, ITEMP, VPOW

Format: 2I2, 1X, 4X, 2I5, E15.0

Content: LA = 5

LB = 66


ITEMP = Temperature function index for VPOW

VPOW = Baseline or constant visco power coefficient

( 5, 67 ) Data Set - Fluidity

Input: LA, LB, U1, MID, ITEMP, FLUID

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 5

LB = 67

U1 = Units for fluidity

= 1 for 1 / seconds

= 2 for 1 / minutes


ITEMP = Temperature function index for FLUID

FLUID = Baseline or constant fluidity

( 6, 0 ) Data Set - Neumann boundary conditions, pointer data

Input: LA, LB, IEL, FACE, INDEX, IFLAG


Content: LA = 6

LB = 0


FACE = Element face number ( see Note A )


IFLAG = 1 if face participates in view factor calculations

= 0 otherwise or if element is 1D



( 6, 1 ) Data Set - Neumann boundary conditions, supplementary data

Input: LA, LB, U1, U2, U3, INDEX, ITIMQ, ITIMH, ITIME, ITIMT,

ITEMH, ITEME, Q, H, EPS, TA

Format: 2I2, 1X, 3I1, 2X, 7I3, 4E12.0

Content: LA = 6

LB = 1

U1 = Units for heat flux

= 1 for W / m**2

= 2 for cal / cm**2 / sec

= 3 for cal / mm**2 / sec

= 4 for Btu / ft**2 / sec

= 5 for Btu / in**2 / sec

= 6 for cal / cm**2 / min

= 7 for Btu / ft**2 / min

= 8 for Btu / in**2 / min

U2 = Units for heat transfer coefficient

= 1 for W / m**2 / K








U3 = Units for ambient temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

INDEX = Corresponds to INDEX in set ( 6, 0 )

ITIMQ = Time function index for Q

ITIMH = Time function index for H

ITIME = Time function index for EPS

ITIMT = Time function index for TA

ITEMH = Temperature function index for H

ITEME = Temperature function index for EPS

Q = Specified heat flux

H = Convection heat transfer coefficient

EPS = Epsilon for radiative heat transfer

TA = Ambient temperature

( 6, 2 ) Data Set - Coincident node information

Input: LA, LB, IEL1, FACE1, IEL2, FACE2, IH

Format: 2I2, 1X, I7, I5, I7, 2I5

Content: LA = 6

LB = 2

IEL1 = Element 1

FACE1 = Coincident face of element 1 ( see Note A )

IEL2 = Element 2

FACE2 = Coincident face of element 2 ( see Note A )

IH = Pointer to Data Set ( 6, 3 )

Note: The temperature of the face of element 1 is used in determining a value from the temperature function.



( 6, 3 ) Data Set - Interface heat transfer coefficients

Input: LA, LB, U1, INDEX, TIME, TEMP, H

Format: 2I2, 1X, I1, 4X, 3I5, E15.0

Content: LA = 6

L1 = 3

U1 = Units for heat transfer coefficient

= 1 for W / m**2 / K








INDEX = Corresponds to IH in Data Set ( 6, 2 )


TEMP = Temperature function number

H = Value of interface heat transfer coefficient

( 6, 4 ) Data Set - Enclosure faces for view factor radiation model

Input: LA, LB, INDEX1, INDEX2, NODE1, ... NODE4

Format: 2I2, 1X, 2I5, 4I7

Content: LA = 6

LB = 4

INDEX1 = Index of temperature and emissivity data in Data Set ( 6, 6 )

INDEX2 = Index of velocity data in Data Set ( 6, 5 )

NODE1, = Connectivity in bar, triangular, or quadrilateral face

...NODE*

( 6, 5 ) Data Set - Velocity data for moving enclosure faces or solid elements

Input: LA, LB, U1, INDEX, TIME, U, V, W

Format: 2I2, 1X, I1, 4X, 2I5, 3E15.0

Content: LA = 6

LB = 5

U1 = Units for enclosure velocity

= 1 for meters / sec

= 2 for centimeters /sec

= 3 for mm / sec

= 4 for feet / sec

= 5 for inches / sec

= 6 for meters / min

= 7 for centimeters /min

= 8 for feet / min

= 9 for inches / min

INDEX = Corresponds to INDEX2 in set ( 6, 4 )


U,V,W = X, Y, Z components of velocity



( 6, 6 ) Data Set - Temperature and emissivity data for enclosure faces

Input: LA, LB, U1 , INDEX, TIME, TEMP, FATEM, EPS

Format: 2I2, 1X, I1, 4X, 3I5, 2E15.0

Content: LA = 6

LB = 6

U1 = Units for face temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

INDEX = Corresponds to INDEX1 in set ( 6, 4 )

TIME = Time function number for FATEM

TEMP = Temperature function number for EPS

FATEM = Face temperature

EPS = Emissivity ( epsilon )

( 6, 7 ) Data Set - Multipoint constraints

Input: LA, LB, SLAVE, M1, W1, M2, W2, M3, W3, M4, W4

Format: 2I2, 1X, I5, 4(I5,E12.0)

Content: LA = 6

LB = 7

SLAVE = Number of node which is constrained

M1-M4 = Master nodes

W1-W4 = Weights associated with each master node

Note: A slave node may be constrained by 1 to 4 other nodes

( 6, 8 ) Data Set - Volumetric heat sources

Input: LA, LB, U1, IEL, TIME, TEMP, VALUE

Format: 2I2, 1X, I1, 4X, 3I5, E15.0

Content: LA = 6

LB = 8

U1 = Units for volumetric heat source

= 1 for W / m**3

= 2 for cal / cc / sec

= 3 for Btu / ft**3 / sec

= 4 for Btu / in**3 / sec

= 5 for cal / cc / min

= 6 for Btu / ft**3 / min

= 7 for Btu / in**3 / min



TEMP = Temperature function number

VALUE = Value of volumetric heat source

( 6, 9 ) Data Set - Linked Periodic Node List

Input: LA, LB, M1, N1, I1, M2, N2, I2, M3, N3, I3, M4, N4, I4


Contents: LA = 6

LB = 9

M1-M4 = Node in the first periodic region

N1-N4 = Node in the second periodic region, associated with M1-M4

I1-I4 = Periodic index pointing to Data Sets ( 4 6 ) and/or ( 4 7 )

( 6, 10 ) Data Set - Symmetry boundary condition

Input: LA, LB, IEL, FACE




Content: LA = 6

LB = 10


FACE = Element face number ( see Note A )

( 6, 11 ) Data Set - Vent boundary condition

Input: LA, LB, U1, U2, U3, U4, NODE, ITIME, P_EXIT, DIAM, ROUGH, LENGTH

Format: 2I2, 1X, 4I1, 1X, 2I7, 4E15.0

Content: LA = 6

LB = 11

U1 = Units for pressure

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2

U2,U3,U4 = Units of length for DIAM, ROUGH, and LENGTH

= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

NODE = Casting side node number where vent is attached

ITIME = Time function index for P_EXIT

P_EXIT = Pressure at exit of vent

DIAM = Vent diameter

ROUGH = Vent surface roughness

LENGTH = Vent equivalent length

( 6, 12 ) Data Set - Gas Injection Boundary Condition

Input: LA, LB, U1, NODE, TIME, PRES, MDOT

Format: 2I2, 1X, I1, 4X, 3I5, E15.0

Content: LA = 6

LB = 12

U1 = Units for mass flux

= 1 kg / sec

= 2 g / sec

= 3 lb / sec

= 4 kg / min

= 5 g / min

= 6 lb / min

NODE = Node that marks the location of the injection site

TIME = Time function number modifying MDOT

PRES = Pressure function number modifying MDOT

MDOT = Gas injection mass flow rate



( 6, 13 ) Data Set - Virtual Mold Data

Input: LA, LB, U1, ELEM, FACE, MAT, GEOM, IHTC, PT

Format: 2I2, 1X, I1, 2X, 5I5, E15.0

Content: LA = 6

L1 = 13

U1 = Units of length for penetration thickness

= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

ELEM = Element number

FACE = Face number

MAT = Material id number, pointing to Data Set ( 3 1 )

GEOM = Geometry type

= 1 for slab

= 2 for cylinder

= 3 for spherical

IHTC = Interface heat transfer pointing to Data Set ( 6 3 )

PT = Penetration thickness of mold

( 6, 15 ) Data Set - Surface load faces

Input: LA, LB, ELEM, FACE, INDEX


Content: LA = 6

L1 = 15


FACE = Face number

INDEX = Pointer to Data Set ( 6 16 )

( 6, 16 ) Data Set - Surface load data

Input: LA, LB, U1, INDEX, ITIME, XLOAD, YLOAD ZLOAD

Format: 2I2, 1X, I1, 2X, 2I5, 3E15.0

Content: LA = 6

L1 = 16

U1 = Units for surface load

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2

INDEX = Data set index

ITIME = Time function index for surface load

XLOAD, = Components of the surface load

YLOAD,

ZLOAD



( 6, 17 ) Data Set - Point load

Input: LA, LB, U1, NODE, ITIME, XLOAD, YLOAD, ZLOAD

Format: 2I2, 1X, I1, 2X, 2I5, 3E15.0

Content: LA = 6

L1 = 17

U1 = Units for point load

= 1 for dynes

= 2 for Newtons

= 3 for lbs

ITIME = Time function index for point load

XLOAD, = Components of the point load

YLOAD,

ZLOAD

( 6, 18 ) Data Set - Non-aligning interface

Input: LA, LB, U1, INDEX, MID1, MID2, IHTC, TOL1, TOL2

Format: 2I2, 1X, I1, 2X, 4I5, 2E15.0

Content: LA = 6

L1 = 18

U1 = Units for TOL1 and TOL2

= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

INDEX = Non-aligning interface index

MID1 = Material id 1

MID2 = Material id 2

IHTC = Pointer to Data Set ( 6 3 )

TOL1 = In-plane tolerance

TOL2 = Perimeter tolerance

( 6, 19 ) Data Set - Fluid momentum sources

Input: LA, LB, U1, ELEM, ITIME, XMOM, YMOM, ZMOM

Format: 2I2, 1X, I1, 2X, 2I5, 3E15.0

Content: LA = 6

L1 = 19

U1 = Units for momentum source

= 1 for Newton / cubic meter

= 2 for dyne / cubic centimeter

= 3 for lb / cubic feet

= 4 for lb / cubic inch


ITIME = Time function for the momentum source

XMOM, = Components of the momentum source

YMOM,

ZMOM



( 6, 20 ) Data Set - Free surface heat flux

Input: LA, LB, MID, INDEX


Content: LA = 6

L1 = 20


INDEX = Pointer to Data Set ( 6 1 )

( 6, 21 ) Data Set - Fluid mass source

Input: LA, LB, U1, U2, U3, INDEX, TIMT, TIMS, TIMX, TIMY, TIMZ,

TEMP, MDOT, X, Y, Z

Format: 2I2, 1X, 3I1, 2X, 6I5, 5E12.0

Content: LA = 6

L1 = 21

U1 = Units for source temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

U2 = Units for source mass flow rate

= 1 for Kg / sec

= 2 for g / sec

= 3 for lb / sec

= 4 for Kg / min

= 5 for g / min

= 6 for lb / min

U3 = Units of the coordinates X, Y, Z

= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

INDEX = Fluid source index

TIMT = Time function for the source temperature

TIMS = Time function for the source mass flow rate

TIMX, = Time function for the source position

TIMY,

TIMZ

TEMP = Temperature of the source

MDOT = Mass flow rate of the source

X, = Source position

Y,

Z



( 6, 22 ) Data Set - Current Density

Input: LA, LB, U1, MID, ITIME, CURRENT

Format: 2I2, 1X, I1, 2X, 2I5, E12.0

Content: LA = 6

L1 = 22

U1 = Units for current density

= 1 for amps / ( meters **2 )

= 2 for amps / ( centimeters ** 2 )

= 3 for amps / ( millimeters ** 2 )

= 4 for amps / ( feet ** 2 )

= 5 for amps / ( inches ** 2 )


ITIME = Time function for current density

CURRENT = current density

( 7, 0 ) Data Set - Dirichlet B.C. - Fixed Temperature

Input: LA, LB, U1, NODE, TIME, FIXVAL

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 0

U1 = Units for fixed temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

NODE = Node number


FIXVAL = Value of fixed temperature

( 7, 1 ) Data Set - Dirichlet B.C. - Fixed U Velocity

Input: LA, LB, U1, NODE, INDEX, FIXVAL

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 1

U1 = Units for fixed velocity

= 1 for m / sec

= 2 for cm / sec

= 3 for mm / sec

= 4 for ft / sec

= 5 for in / sec

= 6 for m / min

= 7 for cm / min

= 8 for ft / min

= 9 for in / min

NODE = Node number


FIXVAL = Value of fixed velocity



( 7, 2 ) Data Set - Dirichlet B.C. - Fixed V Velocity


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 2


= 1 for m / sec

= 2 for cm / sec

= 3 for mm / sec

= 4 for ft / sec

= 5 for in / sec

= 6 for m / min

= 7 for cm / min

= 8 for ft / min

= 9 for in / min

NODE = Node number



( 7, 3 ) Data Set - Dirichlet B.C. - Fixed W Velocity


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 3


= 1 for m / sec

= 2 for cm / sec

= 3 for mm / sec

= 4 for ft / sec

= 5 for in / sec

= 6 for m / min

= 7 for cm / min

= 8 for ft / min

= 9 for in / min

NODE = Node number





( 7, 4 ) Data Set - Dirichlet B.C. - Fixed Pressure


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 4

U1 = Units for fixed pressure

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2

NODE = Node number


FIXVAL = Value of fixed pressure

( 7, 5 ) Data Set - Dirichlet B.C. - Fixed turbulence intensity

Input: LA, LB, NODE, ITIME, INTENS

Format: 2I2, 5X, 2I5, E15.0

Content: LA = 7

LB = 5

NODE = Node number

ITIME = Time function number for turbulence intensity

INTENS = Value of turbulence intensity as a fraction

Note: The turbulence kinetic energy at a prescribed node is calculated as

k = 0.5 * ( INTENS **2 ) * ( u**2 + v**2 + w**2 ).

( 7, 6 ) Data Set - Dirichlet B.C. - Fixed turbulence length scale

Input: LA, LB, U1, NODE, ITIME, LENGTH

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 6

U1 = Units for turbulence length scale

= 1 for meters

= 2 for centimeters

= 3 for millimeters

= 4 for feet

= 5 for inches

NODE = Node number

ITIME = Time function number for turbulence length scale

LENGTH = Value of turbulence length scale

Note: The corresponding turbulence dissipation rate is calculated as

e = CMU * k**1.5 / LENGTH.

U1 CMU = .09 by default, but can be modified in the prefixp.dat file.



( 7, 7 ) Data Set - Dirichlet B.C. - Additional Information

Input: LA, LB, INDEX, TIME, PRES, FILLIM

Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 7

INDEX = Corresponds to INDEX in Data Sets ( 7, 1 ), ( 7, 2 ), and ( 7, 3 )


PRES = Pressure function number

FILLIM = Percentage of volume filled before stopping inlet flow

( 7, 8 ) Data Set - Rotating nodes

Input: LA, LB, NODE

Format: 2I2, 5X, I7

Content: LA = 7

LB = 8

NODE = Node number

Note: Nodes in this list will be given the angular velocity as specified in the 4 8 cards. If no 7 8 cards are used,

then the no-slip nodes will be given the angular velocity

( 7, 10 ) Data Set - Dirichlet B.C. - Fixed X displacement


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 10

U1 = Units for fixed displacement

= 1 for meter

= 2 for centimeter

= 3 for millimeter

= 4 for feet

= 5 for inch

NODE = Node number


FIXVAL = Value of fixed X displacement

( 7, 11 ) Data Set - Dirichlet B.C. - Fixed Y displacement


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 11


= 1 for meter

= 2 for centimeter

= 3 for millimeter

= 4 for feet

= 5 for inch

NODE = Node number


FIXVAL = Value of fixed Y displacement



( 7, 12 ) Data Set - Dirichlet B.C. - Fixed Z displacement


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 12


= 1 for meter

= 2 for centimeter

= 3 for millimeter

= 4 for feet

= 5 for inch

NODE = Node number


FIXVAL = Value of fixed Z displacement

( 7, 13 ) Data Set - Dirichlet B.C. - Fixed magnetic potential


Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA = 7

LB = 13

U1 = Units for fixed magnetic potential

= 1 for Weber / meter

= 2 for Weber / centimeter

= 3 for Weber / millimeter

= 4 for Weber / feet

= 5 for Weber / inch

NODE = Node number


FIXVAL = Value of fixed magnetic potential

Note: The magnetic potential is usually set to zero in the far field.

( 8, 0 ) Data Set - Non-uniform I.C. - Temperature

Input: LA, LB, U1, NODE, TIC

Format: 2I2, 1X, I1, 4X, I5, E15.0

Content: LA = 8

LB = 0

U1 = Units for non-uniform initial temperature

= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

NODE = Node number

TIC = Initial temperature for NODE



( 8, 1 ) Data Set - Non-uniform I.C. - U Velocity

Input: LA, LB, U1, NODE, VIC

Format: 2I2, 1X, I1, 4X, I5, E15.0

Content: LA = 8

LB = 1

U1 = Units for non-uniform initial velocity

= 1 for m / sec

= 2 for cm / sec

= 3 for mm / sec

= 4 for ft / sec

= 5 for in / sec

= 6 for m / min

= 7 for cm / min

= 8 for ft / min

NODE = Node number

VIC = Initial u velocity for NODE

( 8, 2 ) Data Set - Non-uniform I.C. - V Velocity


Format: 2I2, 1X, I1, 4X, I5, E15.0

Content: LA = 8

LB = 2


= 1 for m / sec

= 2 for cm / sec

= 3 for mm / sec

= 4 for ft / sec

= 5 for in / sec

= 6 for m / min

= 7 for cm / min

= 8 for ft / min

NODE = Node number

VIC = Initial v velocity for NODE

( 8, 3 ) Data Set - Non-uniform I.C. - W Velocity


Format: 2I2, 1X, I1, 4X, I5, E15.0

Content: LA = 8

LB = 3


= 1 for m / sec

= 2 for cm / sec

= 3 for mm / sec

= 4 for ft / sec

= 5 for in / sec

= 6 for m / min

= 7 for cm / min

= 8 for ft / min

NODE = Node number

VIC = Initial w velocity for NODE



( 8, 4 ) Data Set - Non-uniform I.C. - Pressure

Input: LA, LB, U1, NODE, PIC

Format: 2I2, 1X, I1, 4X, I5, E15.0

Content: LA = 8

LB = 4

U1 = Units for non-uniform initial pressure

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2

NODE = Node number

PIC = Initial pressure for NODE

( 9, X ) Data Set - Linear Temperature Function

Input: LA, LB, U1, CURVE, POINT, TEMP, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0

Content: LA = 9

LB = 0 for conductivity

LB = 1 for film coefficient

LB = 2 for interface heat transfer

LB = 3 for face emissivity

LB = 4 for enclosure emissivity

LB = 5 for volumetric heat source

LB = 6 for density

LB = 7 for specific heat

LB = 8 for viscosity

LB = 9 for fraction solid

LB = 10 for surface tension

LB = 11 for partition coefficient

LB = 12 for diffusivity

LB = 13 for substrate density

LB = 14 for phase shift coefficient

LB = 15 for power law coefficient

LB = 16 for Yasuda coefficient

LB = 17 for filter interface heat transfer coefficient

LB = 18 for elastic modulus

LB = 19 for Poisson ratio

LB = 20 for thermal expansion

LB = 21 for yield stress

LB = 22 for strength parameter

LB = 23 for hardening parameter

LB = 24 for hardening exponent

LB = 25 for visco-plasticity power coefficient

LB = 26 for fluidity parameter

LB = 27 for magnetic permeability

LB = 28 for electrical conductivity


= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine

CURVE = Function number




TEMP = Temperature of the point

VALUE = Function value of the point

( 10, X ) Data Set - Time Function

Input: LA, LB, U1, CURVE, POINT, TIME, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0

Content: LA = 10

LB = 0 for specified heat flux


LB = 2 for ambient temperature

LB = 3 for fixed temperature


LB = 5 for enclosure face velocity

LB = 6 for enclosure face temperature


LB = 8 for fixed velocity

LB = 9 for fixed pressure


LB = 11 for maximum time step

LB = 12 for gas injection mass flux

LB = 13 for gravity vector rotation angle

LB = 14 for turbulence intensity

LB = 15 for turbulence characteristic length

LB = 16 for gas vent pressure

LB = 17 for angular velocity

LB = 18 for displacement


LB = 20 for surface load

LB = 21 for point load

LB = 22 for momentum source

LB = 23 for mass source flow rate

LB = 24 for mass source temperature

LB = 25 for mass source x position

LB = 26 for mass source y position

LB = 27 for mass source z position

LB = 28 for moving solid velocity

LB = 29 for current density

LB = 30 for magnetic potential

U1 = Units for time

= 1 for sec

= 2 for min



TIME = Time of the point




( 11, X ) Data Set - Quadratic Temperature Function

Input: LA, LB, U1, CURVE, POINT, TEMP, A, B, C

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0

Content: LA = 11

LB = 0 for conductivity




LB = 4 for enclosure emissivity


LB = 6 for density

LB = 7 for specific heat

LB = 8 for viscosity

LB = 9 for fraction solid

LB = 10 for surface tension

LB = 11 for partition coefficient

LB = 12 for diffusivity


LB = 14 for phase shift coefficient

LB = 15 for power law coefficient

LB = 16 for Yasuda coefficient


LB = 18 for elastic modulus

LB = 19 for Poisson ratio

LB = 20 for thermal expansion

LB = 21 for yield stress

LB = 22 for strength parameter

LB = 23 for hardening parameter

LB = 24 for hardening exponent

LB = 25 for visco-plasticity power coefficient

LB = 26 for fluidity parameter

LB = 27 for magnetic permeability

LB = 28 for electrical conductivity


= 1 for Kelvin

= 2 for Celsius

= 3 for Fahrenheit

= 4 for Rankine



TEMP = Temperature of the point

A = Constant coefficient

B = Coefficient of temperature

C = Coefficient of temperature squared



( 12, X ) Data Set - Pressure Function

Input: LA, LB, U1, CURVE, POINT, PRES, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0

Content: LA = 12

LB = 0 for density

LB = 1 for fixed velocity

LB = 2 for gas injection mass flux

U1 = Units for pressure

= 1 for N / m**2

= 2 for Pa

= 3 for KPa

= 4 for MPa

= 5 for bar


= 7 for atm

= 8 for psia

= 9 for lb / ft**2



PRES = Pressure of the point


( 13, X ) Data Set - Cooling Rate Function

Input: LA, LB, U1, CURVE, POINT, CRATE, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0

Content: LA = 13


LB = 1 for transformation temperature

LB = 2 for lamellar spacing

U1 = Units for cooling rate

= 1 for K / sec

= 2 for C / sec

= 3 for F / sec

= 4 for R / sec

= 5 for K / min

= 6 for C / min

= 7 for F / min

= 8 for R / min



CRATE = Cooling rate of the point




( 14, X ) Data Set - Concentration Function

Input: LA, LB, U1, CURVE, POINT, CONC, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0

Content: LA = 14

LB = 0 for liquidus slope

U1 = Units for concentration

= 1 for 1 / m**3

= 2 for 1 / cm**3

= 3 for 1 / mm**3

= 4 for 1 / ft**3

= 5 for 1 / in**3



CONC = Cooling rate of the point


( 99, 0 ) Data Set - Terminator

Input: LA, LB

Format: 2I2

Content: LA = 99 to terminate the data file

LB = 0



Note A:

Brick Element

Face Local Nodes

1 1 4 3 2

2 1 2 6 5

3 2 3 7 6

4 3 4 8 7

5 4 1 5 8

6 5 6 7 8



4 Node Tetrahedral Element

Face Local Nodes

1 1 3 2

2 2 4 1

3 2 3 4

4 4 3 1



Wedge Element

Face Local Nodes

1 1 3 2 -

2 4 5 6 -

3 1 2 5 4

4 2 3 6 5

5 3 1 4 6



Quadrilateral Element

Face Local Nodes

1 1 2

2 2 3

3 3 4

4 4 1



Triangle El ement

Face Local Nodes

1 1 2

2 2 3

3 3 1



10 Node Tetrahedral Element

Face Local Nodes

1 1 3 2 7 6 5

2 2 4 1 9 8 5

3 2 3 4 6 10 9

4 4 3 1 10 7 8




Documents

Procast Manual