FLOW-3D Cast New features since Conifer Cast 3.0 Using FLOW-3D 9.3 solver New limited version solvers ”Basic” and ”Extended” Improved restart file logic Casting metadata Simulation versioning Counter rotating metal inflow Limiting heat transfer calculation to mould core during filling Importing result data in text format Defining metal input fill rate as fill time or mass/time function Defining rotation center for rotating objects Postprocessing improvements

Using FLOW-3D 9.3 solver Improvements in FLOW-3D solver over Performance improvements Convergence improvements Limiting heat transfer calculation for obstacles to specified depth Reliability and convergence improvements GMRES implicit viscous solver convergence has been improved Implicit adiabatic bubble model convergence has been improved Stability and accuracy of the lost foam model has been improved Stability of the implicit advection method has been improved

New limited version solvers ”Basic” and ”Extended” The old limited functionality versions ”Gravity” and ”HPDC” are replaced with new ”Basic” and ”Extended” versions New feature selections match better typical user requirements More mesh blocks are allowed Detailed breakout of the features in each versions is presented in a separate leaflet

Improved restart file logic The restart file logic has been completely reworked Each simulation is now calculated within a separate *.CAL directory The restart simulations refer to source simulations *.CAL directory. The initial data for simulation is loaded from there The new logic allows one to easily make several restarts from same simulation (i.e. restart branches) New mechanism is much more logical and easier to understand

Casting metadata Each simulation can be attached with information about the real world case it relates to. Information includes: Customer to who'm the case relates to Part id/name/version Free description field for storing reason for the simulation and comments about the possible findings Simulation history indicating who prepared/ran the simulation and when

Simulation versions In practice the simulations are often run several times with minor alterations in meshing, parameters etc. To better embrace this a simulation versioning feature has been added: A new simulation version starts with version number as 1 When simulation is run and after that changes are made to the simulation definition the version number is increased. When new simulation version is run it will not overwrite the old version Version specific comment can be added in casting metadata indicating why the new version was made Each restart run versions separately i.e. one can have several versions of restart runs restarting from same initial simulation version.

Counter rotating metal inflow For centrifugal castings Metal inflow from mesh border can now be defined to counter rotate against intertial frame rotation This is useful in centrifucal castings that are modeled so that the calculation mesh rotates along with the rotating mould. Because in the real world the incoming metal does not rotate along with the mould in the simulation domain it needs to counterrotate in relation to the calculation mesh.

Limiting heat transfer calculation to mould core during filling 1/2 Limiting heat transfer simulation to give depth in obstacles: Typically in the casting process the filling takes quite a short time related to the solidification phase. As a result the heat does not have much time to penetrate very far to the mould during the filling.

Limiting heat transfer calculation to mould core during filling 2/2 New option in solid object properties allows user to define maximum heat transfer evaluation depth for solid obstacles (such as the mould). Solver will only calculate the the heat transfer up to this depth from open surface. This can lead to significant performance improvements in filling simulations with heat transfer evaluation enabled.

Importing result data in text format In addition to importing result data from FLOW-3D result files the FLOW-3D Cast 3.1 can also import result data from text files This functionality is mainly suitable for research organizations that are already using FLOW-3D Cast and FLOW-3D Import format is a simple list of coordinates followed by result variable values for each coordinate Coordinates must correspond to a mesh that is already present in the results This mechanism is suitable for visualizating results from users own external calculation modules

Defining metal input fill rate as fill time or mass/time function Additional ways to specify metal input fill rate In Conifer Cast 3.0 the metal inflow rate from metal inputs could only be specified as volume / second (incoming metal volume as a function of time) In FLOW-3D Cast 3.1, additional ways to specify metal inflow has been added Incoming metal mass as a function of time Filling time (inflow rate is estimated from open volume within simulation domain so that open volume gets filled in given time)

Defining metal input fill rate as fill time or mass/time function Additional ways to specify metal input fill rate In Conifer Cast 3.0 the metal inflow rate from metal inputs could only be specified as volume / second (incoming metal volume as a function of time) In FLOW-3D Cast 3.1, additional ways to specify metal inflow has been added Incoming metal mass as a function of time Filling time (inflow rate is estimated from open volume within simulation domain so that open volume gets filled in given time)

Defining rotation center for rotating objects Support for rotating objects is improved In Conifer Cast 3.0 the rotating object rotation center was always the objects mass center In FLOW-3D Cast the rotation center coordinate can be given

Postprocessing improvements 1/3 Postprocessing changes Picking points from results view. User can now use ”pick point” tool to select points from results view. Earlier picking points only worked for STL geometries. Visualizing narrow metal layers. New option ”enchance thin wall” has been added to postprocessing. In some cases this will show very narrow metal walls better.

Postprocessing improvements 2/3 Showing result data as a function of time in a selected point (thermocouples). Once user has selected a point with ”pick point” tool user as a new option available. That is ”show result data”. This will open a new dialog from which user can select a result variable and view the value of the selected variable as a function of time in the selected point.

Postprocessing improvements 3/3 The 'Show Volume' function in the postprocessing has an additional option 'Complement'. This will show the closed volume instead of open volume as transparent. FLOW-3D Cast now allows capturing screen captures and videos larger than the screen size. When getting a capture a scaling factor is asked from the user. Postprocessing results from FLOW-3D/MP. FLOW-3D Cast can now also import and postprocess result data from FLOW-3D/MP (cluster version of FLOW-3D).