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This example tutorial goes through the steps of setting up and running a typical sand casting
analysis. The tutorial begins with a meshed geometry, assigns the process parameters and
completes the solution.
The mesh used in this tutorial is a coincident mesh, in which nodes are shared between regions
or materials. There is a slight difference in the setup if a non-coincident mesh (nodes are not
shared between regions) is used or if an optimized coincident mesh is used. Whenever
differences occur in the setup because of the use of these other meshes, a message concerning
these alternative methods will be noted in the Extra Notes section.
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1. precast sand
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When the mesh is completely read in, you will
see a mesh information form like the one
shown to the right. This form helps to confirm
that the correct number of entities (nodes,
elements) are imported.
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To see the geometry, one simply needs to
press any of the other buttons on the top row of
the PreCAST window. The control of how the
model is viewed is done by hot keys, mouse
functions and/or buttons and forms. These
controls are described in more detail in Section
1 of the ProCAST Users’ Manual.
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Press SHIFT+X
Press SHIFT+Y
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Click on #1
Highlight the material SAND_Silica in the
Material Database
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Click on #2
Highlight the material IRON_Ductile in the
Material Database
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Toggle to Casting in the Type column.
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Click on #3
Highlight the material SAND_Zircon in the
Material Database
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Click on #4
Highlight the material SAND_Zircon in the
Material Database
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The first interface we will enter is that between
the mold and casting.
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Enter .006
Change the units to cal/cm /C/sec
2
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This entry defines the casting / core interface.
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Enter .004
Change the units to cal/cm /C/sec
2
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This entry defines the mold / core interface.
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Enter .002
Change the units to cal/cm /C/sec
2
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Toggle “No” to “Yes” for all material pairs
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Non-Coincident Mesh:
The &5($7( button will be highlighted red and is
inaccessible as PreCAST cannot determine the
material pairs in this type of mesh. Skip this page
and go on to the next page, Interface Assignments.
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Click on the first material ID in material pair 1
Highlight the “Iron_Silica” entry.
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Click on the first material ID in material pair 2
Highlight the “Silica_Zircon” entry.
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Click on the first material ID in material pair 3
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Click on the first material ID in material pair 4
Highlight the “Iron_Zircon” entry.
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Click on the first material ID in material pair 5
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Non-Coincident Mesh:
Before assigning database entries, you must add the
interface pairs. To do this, press ADD, enter the
material pair separated by a space (ie, 1 2) and press
APPLY. Do this for all materials between which
you want to specify an interface.
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Enter .0015
Change the units to cal/cm /C/sec
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Enter 2450
Change units to F
Enter “pouring_temp”
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Enter 0 for U
Enter -21 for V
Enter 0 for W
Change units to in/sec
Enter “pouring_rate”
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Non-Coincident Mesh:
After entering the velocity boundary condition
described above, ADD a new velocity boundary
condition that has U, V and W set to 0. Name this
boundary condition “no_slip”. This is used to
define the region that the flow is allowed to occupy.
This boundary condition is automatically defined
when using a Coincident mesh.
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Highlight the “pouring_rate” Velocity database
entry
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Select a node on the downsprue inlet surface
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Enter “5”
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Before completing the steps above:
• $'' a 9(/2&,7< condition
• Highlight the “no_slip” velocity boundary Note that when the same region has been selected
condition in the database for separate boundary conditions of the same type
• $66,*1 the database entry (ie, velocity), the selection of the last boundary
condition will override previous selections. Thus,
• Use 0$76(/(&7 and highlight only the
even though all of the casting nodes are stored for
casting material, press $33/< the “no slip” velocity, the “pouring_rate” selection
• Press 6(/(&7$// of the inlet surface removes those same nodes from
• 6725( the selection the “no slip” condition.
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Highlight the “pouring_temp” Temperature
database entry
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Highlight the inlet velocity boundary condition
in the BC Set Form (not the database form)
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Highlight the “convection” Heat database entry
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Enter –9.8 as the Y value.
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Highlight Material 1
Change the Units to F
Enter 100 (pressing “Enter” moves the
highlight bar to the next material)
Enter 2450
Enter 100
Enter 100
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The last process parameter we need to define
is specifying the empty cavity.
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Toggle No to Yes for the casting Material
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Change the value of NSTEP to 1000
See next page for illustrations.
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Change the value of TFREQ to 5
See next page for illustrations.
Change the value of QFREQ to 25
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Change the value of FLOW to 3
See next page for illustrations.
Change the value of VFREQ to 5
Change the value of FREESF to 1
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datacast sand
procast sand
prostat sand (in another window)
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