FLOW-3D Cast 3.1.1FLOW-3D Cast 3.1.1

New features since Conifer Cast 3.0New features since Conifer Cast 3.0

Using FLOW-3D 9.3 solverUsing FLOW-3D 9.3 solver

New limited version solvers ”Basic” and ”Extended”New limited version solvers ”Basic” and ”Extended”

Improved restart file logicImproved restart file logic

Casting metadataCasting metadata

Simulation versioningSimulation versioning

Counter rotating metal inflowCounter rotating metal inflow

Limiting heat transfer calculation to mould core during fillingLimiting heat transfer calculation to mould core during filling

Importing result data in text formatImporting result data in text format

Defining metal input fill rate as fill time or mass/time functionDefining metal input fill rate as fill time or mass/time function

Defining rotation center for rotating objectsDefining rotation center for rotating objects

Postprocessing improvementsPostprocessing improvements

Using FLOW-3D 9.3 solverUsing FLOW-3D 9.3 solver

Improvements in FLOW-3D 9.3.1 solver over 9.2.1Improvements in FLOW-3D 9.3.1 solver over 9.2.1

Performance improvementsPerformance improvements

Convergence improvementsConvergence improvements

Limiting heat transfer calculation for obstacles to specified depthLimiting heat transfer calculation for obstacles to specified depth

Reliability and convergence improvementsReliability and convergence improvements

GMRES implicit viscous solver convergence has been improvedGMRES implicit viscous solver convergence has been improved

Implicit adiabatic bubble model convergence has been improvedImplicit adiabatic bubble model convergence has been improved

Stability and accuracy of the lost foam model has been improvedStability and accuracy of the lost foam model has been improved

Stability of the implicit advection method has been improvedStability of the implicit advection method has been improved

New limited version solvers New limited version solvers ””Basic” and ”Extended”Basic” and ”Extended”The old limited functionality versions ”Gravity” and ”HPDC” are replaced with new The old limited functionality versions ”Gravity” and ”HPDC” are replaced with new

”Basic” and ”Extended” versions ”Basic” and ”Extended” versions

New feature selections match better typical user requirementsNew feature selections match better typical user requirements

More mesh blocks are allowed More mesh blocks are allowed

Detailed breakout of the features in each versions is presented in a separate Detailed breakout of the features in each versions is presented in a separate

leafletleaflet

Improved restart file logicImproved restart file logicThe restart file logic has been completely reworkedThe restart file logic has been completely reworked

Each simulation is now calculated within a separate *.CAL directoryEach simulation is now calculated within a separate *.CAL directory

The restart simulations refer to source simulations *.CAL directory. The The restart simulations refer to source simulations *.CAL directory. The

initial data for simulation is loaded from thereinitial data for simulation is loaded from there

The new logic allows one to easily make several restarts from same The new logic allows one to easily make several restarts from same

simulation (i.e. restart branches)simulation (i.e. restart branches)

New mechanism is much more logical and easier to understandNew mechanism is much more logical and easier to understand

Casting metadataCasting metadata

Each simulation can be attached with information about the real Each simulation can be attached with information about the real

world case it relates to. Information includes:world case it relates to. Information includes:

Customer to who'm the case relates toCustomer to who'm the case relates to

Part id/name/versionPart id/name/version

Free description field for storing reason for the simulation Free description field for storing reason for the simulation

and comments about the possible findingsand comments about the possible findings

Simulation history indicating who prepared/ran the Simulation history indicating who prepared/ran the

simulation and whensimulation and when

Simulation versionsSimulation versions

In practice the simulations are often run several times with minor In practice the simulations are often run several times with minor

alterations in meshing, parameters etc. To better embrace this a alterations in meshing, parameters etc. To better embrace this a

simulation versioning feature has been added:simulation versioning feature has been added:

A new simulation version starts with version number as 1A new simulation version starts with version number as 1

When simulation is run and after that changes are made to the When simulation is run and after that changes are made to the

simulation definition the version number is increased. When new simulation definition the version number is increased. When new

simulation version is run it will not overwrite the old versionsimulation version is run it will not overwrite the old version

Version specific comment can be added in casting metadata Version specific comment can be added in casting metadata

indicating why the new version was madeindicating why the new version was made

Each restart run versions separately i.e. one can have several Each restart run versions separately i.e. one can have several

versions of restart runs restarting from same initial simulation versions of restart runs restarting from same initial simulation

version.version.

Counter rotating metal inflowCounter rotating metal inflow

For centrifugal castingsFor centrifugal castings

Metal inflow from mesh border can now be Metal inflow from mesh border can now be

defined to counter rotate against intertial frame defined to counter rotate against intertial frame

rotationrotation

This is useful in centrifucal castings that are This is useful in centrifucal castings that are

modeled so that the calculation mesh rotates modeled so that the calculation mesh rotates

along with the rotating mould. along with the rotating mould.

Because in the real world the incoming metal Because in the real world the incoming metal

does not rotate along with the mould in the does not rotate along with the mould in the

simulation domain it needs to counterrotate in simulation domain it needs to counterrotate in

relation to the calculation mesh.relation to the calculation mesh.

Limiting heat transfer calculation to Limiting heat transfer calculation to mould core during filling 1/2mould core during filling 1/2

Limiting heat transfer simulation to Limiting heat transfer simulation to

give depth in obstacles:give depth in obstacles:

Typically in the casting process Typically in the casting process

the filling takes quite a short the filling takes quite a short

time related to the solidification time related to the solidification

phase. As a result the heat phase. As a result the heat

does not have much time to does not have much time to

penetrate very far to the mould penetrate very far to the mould

during the filling.during the filling.

Limiting heat transfer calculation to Limiting heat transfer calculation to mould core during filling 2/2mould core during filling 2/2

New option in solid object properties allows user to define maximum New option in solid object properties allows user to define maximum

heat transfer evaluation depth for solid obstacles (such as the mould). heat transfer evaluation depth for solid obstacles (such as the mould).

Solver will only calculate the the heat transfer up to this depth from Solver will only calculate the the heat transfer up to this depth from

open surface.open surface.

This can lead to significant performance improvements in filling This can lead to significant performance improvements in filling

simulations with heat transfer evaluation enabled.simulations with heat transfer evaluation enabled.

Importing result data in text formatImporting result data in text format

In addition to importing result data from FLOW-3D result files the FLOW-3D In addition to importing result data from FLOW-3D result files the FLOW-3D

Cast 3.1 can also import result data from text filesCast 3.1 can also import result data from text files

This functionality is mainly suitable for research organizations that are This functionality is mainly suitable for research organizations that are

already using FLOW-3D Cast and FLOW-3Dalready using FLOW-3D Cast and FLOW-3D

Import format is a simple list of coordinates followed by result variable Import format is a simple list of coordinates followed by result variable

values for each coordinatevalues for each coordinate

Coordinates must correspond to a mesh that is already present in the Coordinates must correspond to a mesh that is already present in the

resultsresults

This mechanism is suitable for visualizating results from users own This mechanism is suitable for visualizating results from users own

external calculation modulesexternal calculation modules

Defining metal input fill rate as fill time Defining metal input fill rate as fill time or mass/time functionor mass/time function

Additional ways to specify metal input fill rateAdditional ways to specify metal input fill rate

In Conifer Cast 3.0 the metal inflow rate from metal In Conifer Cast 3.0 the metal inflow rate from metal

inputs could only be specified as volume / second inputs could only be specified as volume / second

(incoming metal volume as a function of time)(incoming metal volume as a function of time)

In FLOW-3D Cast 3.1, additional ways to specify In FLOW-3D Cast 3.1, additional ways to specify

metal inflow has been addedmetal inflow has been added

Incoming metal mass as a function of timeIncoming metal mass as a function of time

Filling time (inflow rate is estimated from open Filling time (inflow rate is estimated from open

volume within simulation domain so that open volume within simulation domain so that open

volume gets filled in given time)volume gets filled in given time)

Defining metal input fill rate as fill time Defining metal input fill rate as fill time or mass/time functionor mass/time function

Additional ways to specify metal input fill rateAdditional ways to specify metal input fill rate

In Conifer Cast 3.0 the metal inflow rate from metal In Conifer Cast 3.0 the metal inflow rate from metal

inputs could only be specified as volume / second inputs could only be specified as volume / second

(incoming metal volume as a function of time)(incoming metal volume as a function of time)

In FLOW-3D Cast 3.1, additional ways to specify In FLOW-3D Cast 3.1, additional ways to specify

metal inflow has been addedmetal inflow has been added

Incoming metal mass as a function of timeIncoming metal mass as a function of time

Filling time (inflow rate is estimated from open Filling time (inflow rate is estimated from open

volume within simulation domain so that open volume within simulation domain so that open

volume gets filled in given time)volume gets filled in given time)

Defining rotation center for rotating objectsDefining rotation center for rotating objects

Support for rotating objects is improvedSupport for rotating objects is improved

In Conifer Cast 3.0 the rotating object rotationIn Conifer Cast 3.0 the rotating object rotation

center was always the objects mass centercenter was always the objects mass center

In FLOW-3D Cast 3.1.1 the rotationIn FLOW-3D Cast 3.1.1 the rotation

center coordinate can be givencenter coordinate can be given

Postprocessing improvements 1/3Postprocessing improvements 1/3

Postprocessing changes Postprocessing changes

Picking points from results view. User can Picking points from results view. User can

now use ”pick point” tool to select points now use ”pick point” tool to select points

from results view. Earlier picking points from results view. Earlier picking points

only worked for STL geometries.only worked for STL geometries.

Visualizing narrow metal layers. New Visualizing narrow metal layers. New

option ”enchance thin wall” has been option ”enchance thin wall” has been

added to postprocessing. In some cases added to postprocessing. In some cases

this will show very narrow metal walls this will show very narrow metal walls

better.better.

Postprocessing improvements 2/3Postprocessing improvements 2/3Showing result data as a Showing result data as a

function of time in a selected function of time in a selected

point (thermocouples). Once point (thermocouples). Once

user has selected a point with user has selected a point with

”pick point” tool user as a new ”pick point” tool user as a new

option available. That is ”show option available. That is ”show

result data”. This will open a result data”. This will open a

new dialog from which user can new dialog from which user can

select a result variable and select a result variable and

view the value of the selected view the value of the selected

variable as a function of time in variable as a function of time in

the selected point.the selected point.

Postprocessing improvements 3/3Postprocessing improvements 3/3

The 'Show Volume' function in the postprocessing has an additional The 'Show Volume' function in the postprocessing has an additional

option 'Complement'. This will show the closed volume instead of option 'Complement'. This will show the closed volume instead of

open volume as transparent. open volume as transparent.

FLOW-3D Cast 3.1.1 now allows capturing screen captures and FLOW-3D Cast 3.1.1 now allows capturing screen captures and

videos larger than the screen size. When getting a capture a scaling videos larger than the screen size. When getting a capture a scaling

factor is asked from the user.factor is asked from the user.

Postprocessing results from FLOW-3D/MP. FLOW-3D Cast 3.1.1 can Postprocessing results from FLOW-3D/MP. FLOW-3D Cast 3.1.1 can

now also import and postprocess result data from FLOW-3D/MP now also import and postprocess result data from FLOW-3D/MP

(cluster version of FLOW-3D).(cluster version of FLOW-3D).