PROCAST TUTORIAL PDF

ProCAST simulation software offers an extensive suite of modules and foundry tools to meet your most challenging industrial requirements. ProCAST software, based on powerful Finite Element Technology, is well suited to also predict distortions and residual stresses and can address more specific processes like semi-solid, core blowing, centrifugal, lost foam and continuous casting. ProCAST manufacturing casting tools are some of the most powerful in the industry today, and the robust ProCAST engineering gives you the tools to perform evaluations of all casting processes, for all castable alloys. The tool addresses the basics of any casting process: filling, solidification and porosity prediction including core blowing and semi-solid modeling. QuikCAST meets industrial needs.

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The links are referring to the corresponding section of the manual for more details. A bug in the "Copy" functionnality was corrected. The FlexLM libraries were upgraded from 9. A bug in the status window wrong update of the number of cycles was corrected.

The Surface mesh algorithm was improved in order to have a better quality surface mesh. Especially, cylinders defined by only one surface can now be meshed automatically. Thin cylinders e. The Autofix is now fully automatic no more need to specify a length A functionnality to remove automatically filets was introduced see the MeshCAST manual for more details. The format of the volume mesh has been adapted to allow the handling of files with more than 10 millions elements.

Version In the case of shot piston, it is possible now to define the position of the piston in three different ways : position vs time, velocity vs time, velocity vs position see the "Process Database" section for more details. A new "Pick" function has been introduced, to pick the coordinates and the node number of a given point selected interactively on the model see the "Geometry Manipulation" section for more details. Stress properties Youngs modulus, Poisson Ratio, Expansion coefficient are now automatically calculated, based upon the Thermodynamic databases see "Calculation of Stress Properties" section for more details.

When defining the interfaces, the "Wireframe" mode has been reactivated in order to see a domain which is inside an other one. The Plastic stress properties i. In the case of Microstructure modelling, the default values of the Run parameters were removed see the "Micro Run Parameters" section for more details. The mesh can be now optimized also in the case of Periodic BC.

If a non-coincident mesh is used, a warning prevents the definition of a virtual mould. New User functions have been introduced see "User Functions" section for more details. A problem in the initialization of CORE materials during cycling has been corrected. Thermodynamic databases Stress properties Youngs modulus, Poisson Ratio, Expansion coefficient are now automatically calculated, based upon the Thermodynamic databases see "Calculation of Stress Properties" section for more details.

The latest available Computherm databases are included in this version. The material properties calculated with these databases will be more accurate than the previous ones. This manual describes for each alloying system the phases which are calculated, the limitations as well as the validations which have been made. Temperature, Pressure, The previously defined scales i. When a model is loaded for the first time or when no view was stored , the model is displayed in isometric view, with the gravity pointing downwards.

In case of a Stress calculation, it is now possible to calculate all the Stress results e. The calculation of the solidification time was improved in order to account for remelting if any. The calculation of the Filling time was changed in order to ignore the piping area. Stress results can be viewed also when the directory is in Read-only mode on Windows only.

If more than one symmetry is defined in the model, it can be automatically retrieved it was previously working only with one symmetry. In the case of a Tilt casting, it was mandatory to have the p. This obligation was removed. In the XYPlot window, when nodes were selected interactively, the selection window with the cursors was disappearing each time the model had to be rotated or moved. This limitation is now removed.

Solver The filling algorithm was improved. The filling solver was improved in order to better handle Tilt pouring models. The convergence, the accuracy and the CPU time of the Stress module was significantly improved. Two new models Norton law and Strain Hardening Creep were introduced in the Stress module to account for viscoplasticity and creep see "Stress models and Properties" section for more details.

In the case of Stress calculations with Vacant or Rigid materials, the memory management was changed in order to reduce the amount of memory needed in the scalar version only.

Stress calculations can now be run with piping i. Microstructure models were improved see "Microstructures" section for more details. The memory requirement was significantly reduced when running a case with many materials. Time-dependant Inlet boundary conditions were introduced see the "Boundary Conditions Database" section for more details.

A problem of Restart in the case of gravity casting was corrected. The problem of heat transfer between a shot piston and the casting there was no heat transfer has been solved. The logic of the flow Switch Off was changed in order to avoid some unexpected situations. It is possible now to run Stress models with materials which have no phase change. A bug in the case of Stress calculation in the presence of filters has been corrected. It is possible now to run a Microstructure calculations together with the Turbulent model.

In the case of moving solids, the translation is also called at step 0. A problem in the calculation of the piping when using Periodic Boundary conditions was fixed. A problem in the calculation of the "Freckles predictor" has been corrected, as well as a problem of Restart with Freckles prediction.

If the "statpro" directory where the status file is written is momentarily not available, the calculation will not crash anymore. In the case of delayed filling i. A problem in the Units of the user function "externalcompute.

A problem of "datacast -u" in the case of stress was fixed the stresses of vacant domains were lost. A problem of convergence with non-coincident meshes was fixed. A problem of memory allocation was corrected in the case of Radiation problems. The Run Parameters Recommendations have been updated in order to account for the changes in the algorithm see the "Run Parameters Recommendations" section for more details. Please note that no specific set-up should be done for parallel processing of Stress calculations.

The set-up exactly the same as the scalar version. ProCAST The Lost Foam and the Non-Newtonian module has been parallelized same set-up as the scalar version. Some problems encountered in the DMP versions were fixed. Advanced Porosity module The quality of the solver was significantly improved in order to have a better convergence robustness and a better accuracy of the results.

The defalult value for the "convergence. A bug in the storage frequency was corrected. It is possible to view Advanced Porosity results with the calcososft postprocessor across plateforms automatic swap option.

The calcosoft post-processor allows now to view results calculated using Hex or Wedges mesh. A bug in the viewing of Advanced Porosity results in the presence of enclosures has been corrected.

Template files of the poro. One should note that it is very important to set stress properties according to the "rules" described in Version Othewise, one could have convergence problems see the "Stress Models and Properties" section for more details - end of the section. A new section was added in the "Microstructure Module" chapter see the "Iron and Steel" section for more details.

The suffix ". This version will work with CRO license keys. The possibility to read Parasolid files with the.

The computation algorithm of the Virtual mold was modified to avoid odd behavior in some cases. The virtual mold size can be defined automatically see the "Virtual mold" section for more details. A bug in the units of the "Tilt" axis was corrected.

A bug in the storage of the "K-factor" non-Newtonian model was corrected. The "Extract" was extended in order to allow it in the presence of filters.

A "Erase line" was added in the "Chemical Composition" definition of the material properties. New alloys were introduced in the Material database. Some properties of existing alloys were improved. The Stress material properties database was complemented. A bug in the treatment of non-coincident interfaces was corrected it was creating a double heat transfer on some nodes in some specific cases. Thermodynamic databases The automatic calculation of the "Thermal conductivity" from the thermodynamic databases was introduced for all databases see the "Thermodynamic Databases" section for more details The content of the Computherm databases was improved.

This will lead to more accurate properties predictions. Moreover, the computation of some alloys which was not possible with previous versions was improved. This means that the properties calculated with this version will be different but more accurate than the previous ones e. A problem in the Mg database was fixed, giving now the right results. The liquid density of Pure Aluminium was changed in order to give more accurate density predictions of Al-alloys e.

This will affect the density calculations for all Al alloys. The export of "Reversed displacements" was corrected, as well as the X-Y plots of displacements.

The maximum number of timesteps which could be exported was increased from to In Tilt casting, the particles are now "tilting" with the part.

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