ProCAST 2015.0 ReleaseNotes

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ProCAST 2015
Release Notes & Installation Guide
ProCAST 2015
RELEASE NOTES &

INSTALLATION GUIDE
The documents and related know-how herein provided by ESI Group subject to
contractual conditions are to remain confidential. The CLIENT shall not disclose
the documentation and/or related know-how in whole or in part to any third party
without the prior written permission of ESI Group.
© 2015 ESI Group. All rights reserved.
April 2015
GR/PRCA/15/01/00/A
MESSAGE
Dear Customer,
We are pleased to provide you with the multi-physics code ProCAST 2015 release.
We are delivering one DVD containing ProCAST 2015 (parallel solvers for Windows (64) and
Linux (64) systems), QuikCAST 2014 (Windows (64)) and Visual-Cast 10.7 version (the
compatible environment).
This version has undergone several improvements to consolidate product functionalities and
contains new features. Please refer to the present release notes and to the Visual-Cast on-line
user manual for more details about all the new capabilities and corrections. In particular, we
strongly recommend reading the What's New/Version 2015 or VE 10.7 Release Notes
sections which detail all. Please find below some highlights of these new embedded
developments:
• Platform convergence for Casting Solutions has progressed further. One can use from
the same Visual environment the Finite Element approach (ProCAST solvers) or the
Finite Difference one (QuikCAST solvers). QuikCAST solvers now become a module of
ProCAST.
• An Optimization module has been introduced. Design Of Experiment, Robustness
analysis, Optimization and Inverse modeling (curve fitting) are the different capabilities.
• The dimensionless Niyama porosity model has been introduced and allows micro-
porosity calculations which take into account the alloy properties.
• A new, second generation, Advanced Porosity Module APM (beta version) has been
developed for shrinkage and gas porosity defects, taking into account the liquid
pressure. Performance in terms of memory requirement and solving time (DMP version)
has been significantly improved.
• Standalone Datacast executable is now available.
• CCT and TTT diagrams can be displayed in the corresponding material database.
• Grain structure modeling (CAFE) results in cut section, such as histograms, statistics
and pole figures, have been implemented in Visual.
We wish you a lot of successes with this release. If you have any questions or need further
assistance, please do not hesitate to contact your local support team.
In the meantime, the ESI Group's casting team remains sincerely yours.
ESI GROUP CASTING TEAM

ProCAST 2015 i RELEASE NOTES & INSTALLATION GUIDE
© 2015 ESI Group (released: Apr-15)
CONTENTS
Release Notes 1
Introduction--------------------------------------------------------------------------------- 1
Visual-Cast --------------------------------------------------------------------------------- 2
Optimization Workflow -------------------------------------------------------------------- 2
QuikCAST Support ------------------------------------------------------------------------ 3
CCT and TTT Diagram Display --------------------------------------------------------- 8
Standalone DataCAST-------------------------------------------------------------------- 9
Other Updates ------------------------------------------------------------------------------ 9
Fixed Issues ------------------------------------------------------------------------------- 10
Limitations---------------------------------------------------------------------------------- 10
ProCAST Solver 2015 Updates ------------------------------------------------------ 12
Visual-Mesh (Cast) --------------------------------------------------------------------- 14
CAD Import -------------------------------------------------------------------------------- 14
Change / Convert Length Units ------------------------------------------------------- 14
Surface Selection ------------------------------------------------------------------------ 15
Surface Repair ---------------------------------------------------------------------------- 15
Volume Computation -------------------------------------------------------------------- 16
Topo Mesh --------------------------------------------------------------------------------- 17
Check Surface Mesh -------------------------------------------------------------------- 18
3D Mesh Quality Checks --------------------------------------------------------------- 18
Limitations---------------------------------------------------------------------------------- 18
Visual-Viewer (Cast) ------------------------------------------------------------------- 19
CAFE Histogram ------------------------------------------------------------------------- 19
CAFE Statistics --------------------------------------------------------------------------- 20
CAFE Pole Figure ------------------------------------------------------------------------ 20
Fixed Issues ------------------------------------------------------------------------------- 21
Known Issues ----------------------------------------------------------------------------- 21
Limitations---------------------------------------------------------------------------------- 21
Core Dump Tracker -------------------------------------------------------------------- 23
Installation Guide 25
Software Installation on Windows -------------------------------------------------- 25
Installing the Software ------------------------------------------------------------------ 25
Installing the License -------------------------------------------------------------------- 26
Software Installation on Linux ------------------------------------------------------- 29
Overview ----------------------------------------------------------------------------------- 29
CD-ROM Mounting Instructions ------------------------------------------------------ 30
System Requirement -------------------------------------------------------------------- 30
Installing the Software ------------------------------------------------------------------ 30
Installing the License -------------------------------------------------------------------- 35
Customizing the Installation ----------------------------------------------------------- 40
Release Notes
Introduction
RELEASE NOTES & INSTALLATION GUIDE ii ProCAST 2015
(released: Apr-15) © 2015 ESI Group
Getting Started -------------------------------------------------------------------------- 42

Starting the Software -------------------------------------------------------------------- 42
Online Product Documentation ------------------------------------------------------- 42
myESI Customer Portal --------------------------------------------------------------- 43
Release Notes
Introduction
ProCAST 2015 1 RELEASE NOTES & INSTALLATION GUIDE
RELEASE NOTES
INTRODUCTION
Visual-Environment 10.7 is an update release after VE 10.5 to address customer-
specific requirements in the following applications:
Visual-Cast is the single integrated environment for all of your casting needs. The pre-
processor helps in model set-up, aided by definition of physics on topology and tailored
process flowchart using integrated Visual-Process. Visual-Cast is also linked to
Thermodynamic Databases for the automatic determination of the material properties.
Visual-Mesh (Cast) is a complete meshing tool for Casting and other volume based
applications. This supports a multi-model environment with model explorer and
powerful display controls. It facilitates import of CAD and mesh data from various
sources, repair CAD geometry, assembly of volumes, generation of surface mesh,
validation and correction of surface mesh and finally generation of volume meshes.
Visual-Viewer (Cast) is the visualization and plotting tool that helps in analyzing
ProCAST and QuikCAST results data within a uniform interface. It performs
automated tasks and generates customized reports, thereby increasing engineer
productivity.
Release Notes
Introduction
RELEASE NOTES & INSTALLATION GUIDE 2 ProCAST 2015
VISUAL-CAST
Optimization Workflow
• The Optimization solvers from PAM-OPT are fully integrated with ProCAST
solvers by means of a step-by-step workflow created in Visual-Environment for
process engineers to easily setup, track and post-process the optimization
simulation. The following capabilities are available through this workflow:
· Design of Experiment: This can be used beneficially to detect the sensitivity of a
solution with respect to the variation of the declared design parameters.
· Optimization: This can be used to determine the best set of casting process
parameters for a given objective.
· Robustness Analysis: This can be beneficial in studying the influence of
stochastic parameters on a solution.
· Inverse Modeling (curve fitting): The old ProCAST Inverse module is back with
advanced solvers of PAM-OPT. This can be used to determine thermo-physical
material data or boundary conditions from simple and well controlled
temperature measurements.
Release Notes
Visual-Cast
QuikCAST Support
Platform convergence for Casting Solutions has progressed further. From Visual-
Environment, one can use the Finite Element approach (ProCAST solvers) or the Finite
Difference approach (QuikCAST solvers). QuikCAST solvers have now become a
module of ProCAST.
Grid Definition Support

Basic functionality of grid definition was supported in VE10.5. In the current version,
all remaining functionalities are supported.
• The following options are available:

· Auto: "Uniform" and "Advanced" options are supported.
· Create: Create Gridlines with following options are supported:
 User Keyboard Input
 Points
 Min Extents of Regions
 Max Extents of Regions
 Min. Max. Extents of Regions
Release Notes
Visual-Cast
· Modify: Allows for modification of a grid line location.

· Insert: Allows inserting several grid lines inside of a selected grid line range.
· Delete: Allows deleting several grid lines in a selected grid lines range.
Piston Process Condition
• A new Graphical User Interface (GUI) is developed to define piston process

condition.
• The piston material can be selected using material database selection.
• The piston velocity can be selected using process condition database selection.
• The piston entities can be selected using region and volume selection buttons.
• The "Gate and runner" selection is enabled only for "Velocity calculator" type.
Release Notes
Visual-Cast
Implicit Mold Process Condition
• A new GUI is developed to define Implicit mold process condition.

• The Implicit mold material can be selected using material selection.
• The Implicit mold regions can be selected using region selection button.
• Right-click the "Name" column and click "Add thickness" field for defining mold
thickness for each process condition. The defined thickness will appear in the
bottom of the dialog box.
Release Notes
Visual-Cast
Cooling Process Condition
• The cooling process condition regions can be selected using the region selection
button.
• The history points can be selected using list selection.
• The cooling process condition can be selected using process condition selection.
Release Notes
Visual-Cast
Contact Resistance Process Condition
• The Contact resistance process condition is supported inside interface folder.

• The Contact resistance region can be selected using region selection button.
• The Contact resistance process condition can be selected using process condition
selection.
Existing capabilities of QuikCAST supported in Visual-Cast are as follows:
• PMF file loading for flow and thermal cases
• Ability to define/Edit grid
• Access to QuikCAST material database
• Support of the following Boundary Conditions:
· Hydraulic Conditions: Initial Fluid (Only Initial), Inlet, Pressure (Only
Imposed), Velocity, Flow paths, Permeability, Region Roughness and Piston
· Thermal Conditions: Temperature, Heat Transfer Coefficient, External
Exchange, Die coating, Heat Flux, Thermal coefficients, Die Spray, Mold
Opening, Third stage effect, Implicit Mold, Cooling and Contact Resistance
Release Notes
Visual-Cast
CCT and TTT Diagram Display
• CCT / TTT diagrams are now supported in material editor.

• Selecting a “CCT/TTT Data” in the Microstructure tab will bring up the CCT/TTT
tab.
• The CCT/TTT tab allows creation and edition of user-defined CCT/TTT diagrams
by specifying the Start/End temperatures, Min/Max cooling rates, etc.
Release Notes
Visual-Cast
Standalone DataCAST
Standalone DataCAST executable can be launched using the <VE installation
folder>\Windows-x64\Tools\VDBTools\datacast.cmd batch file.
Usage:
<VE installation folder>\Windows-x64\Tools\VDBTools\datacast.cmd
<vdb_file_prefix><version><options>
with:
• <version>: 20150, 20145, 20140 etc.
• <options>:
o -u: Stands for "update". It should only be used if INILEV is not zero. If
"-u" is used, it means that all the result files (t.unf, u.unf, p.unf...
etc.) from previous calculations are to be kept.
o -v: It writes out coordinate and connectivity data. This may be very
helpful for debugging purposes.
o -d: It checks for zero or negative volumes. Bad elements will be printed
o -coin: It checks for errors in coincident interface and free face
compatibility.
Other Updates
• In Simulation Parameters, the APM tab, an option to enter 3 coordinates of a
pressure point for contiguous casting type, is introduced.
• A second generation of the Advanced Porosity Module APM (beta version) is now
available with new parallel version.
• Pre-defined output criterion (used for Optimization): Mean and Variance options are
added for shrinkage porosity.
• User-defined function capabilities for Displacement in X, Y and Z axes.
• Process conditions with no database or entity assigned are automatically detected
and reported in a warning message that is output in Data Checks reports.
• If the interface Alloy-Filter has been defined as COINC, an error is generated in
Data Checks reports.
• Spraying effect option is now available in Die Combo.
• A Start Simulation > Options tab > “Export d.dat” option has been introduced. If this
option is ON on DataCAST or on RUN, <prefix>d.dat is exported in the project
folder.
Note: this option is still in a BETA state.
Release Notes
Visual-Cast
Fixed Issues
• Inconel 713 solidus property was wrong in the public database. This has been
corrected.
• Enclosure regions coming from .mesh format (6 4 cards) were not listed in the
Process Condition manager. This has been fixed.
• When you opened a d.dat file with a cafe setup (in the folder, where d.dat,
p.dat and mica.d were available), saved the model as vdb and started the
simulation, the mica.d file did not disappear from the folder as expected. This now
works fine.
• When using the Mass Flow Rate Calculator, the initial temperature is set by default
to 273°C. Changing this value to the casting temperature and compute the boundary
conditions resulted in a new temperature which is 273 °C higher than the chosen
casting temperature. This unit conversion issue has been addressed.
• When no material was assigned to a volume and MICRO was ON, the solver RUN
was causing a stability issue. This issue has been fixed.
• When creating a symmetry process condition and frequently changing regions, a
stability issue may occur. This issue has been fixed.
• In some cases, when trying to create a QuikCAST job entirely in Visual and use
Computherm to generate the material data, the QuikCAST solver did not launch.
This issue has been fixed.
• The unit for the average temperature parameter in Die spray was wrong. This issue
has been fixed.
• When a pmf file is imported, the contiguous selection is not always working in
element face. This issue has been fixed.
Limitations
• The following features are not supported in d.dat reading:
· 2D Model: Loading will terminate in this case.
· Reading d.dat files of ProCAST versions previous to 2008.1: these files will
still be loaded for checking and making necessary changes if required in the
GUI.
• Extraction/Mapping functionality is not supported for MILE cases.
• To run the solver from "Start Simulation" GUI, the solver path must contain the
solver version number: 2014.0, 2013.5, etc.
This path should not contain any "." in the path except in the version number.
Release Notes
Visual-Cast
• Loading <prefix>d.dat files with special characters in the material name may
sometimes fail in Linux versions.
It is recommended to edit these files and rename the material by removing special
characters to avoid the problem.
• A "Run List" that uses user-defined functions should be built only for cases that are
located on the same drive.
• In "Start Simulation" -hostlist can be specified only in option1.
• In "Start Simulation" on Windows platform, avoid specifying both -hostlist in
option1 and hostfile together.
• When several files are appended to the existing model, volumes should be checked
for unique name. Unique volume names should be maintained in order to update
regions correctly.
• If mold and alloy are connected by a line of common nodes instead of interfaces, the
solver will throw an error when it is launched. It is recommended to create COINC
nodes at these locations in Visual-Mesh.
• The defined frequencies such as TFREQ, VFREQ, cannot be changed when calling
"Restart". It is recommended to use “extract” and define new TFREQ and VFREQ
frequencies.
• User-defined functions should be always set in CGS units.
• .sm files (for example, with enclosures for radiation problems) should be appended
to the existing model only after loading/appending other files.
• The Stress calculations are not supported in new multi-radius accordion
calculations.
• The computation of m and k values using the back diffusion method on a LINUX
platform is not correct. It is recommended to use Scheil, Lever, or Compute on a
Windows platform.
• APM, HCS, CAFE in post-processor mode are not fully compatible with the new
storage frequency capabilities.
• Ladle Calculator and Mass Flow Calculator panels show temperature values in
Celsius unit. The unit selected in ‘Cast Preferences’ is not reflected in those panels.
• The units selected in ‘Cast Preferences’ are not reflected in the database editor.
• Avoid special characters in project folder path names. The solver will not launch if
the folder name contains special characters.
• QuikCAST is not supported on LINUX platforms.
• When importing ‘vdb’ files saved in a previous version and that contain wrap
process condition values, the 'Heat Vs. Thickness' curve is not displayed in the wrap
database. It is recommended to re-define heat values for a different thickness input
as explained in the user manual.
Release Notes
Visual-Cast
• 'Run Multi-Stage' on LINUX will run the batch file in the same shell window that
will start running the solver. Hence, it is advised to 'Generate' batch file and data
separately, and then launch this batch file.
• During the pmf file import, if default regions have been renamed, then the file
import fails. The file must be renamed manually in QuikCAST and then imported.
• All the Initial conditions imported from a pmf file are treated as "Initial" by default.
When Pressure/Velocity BC is present in the model and these BCs are applied to the
volumes having fill % 100, then the initial fluid condition will be set as "Imposed".
In VE10.5, "Imposed" was the default option.
• All the thermal process conditions are applicable to both Filling and Solidification.
If exemesh fails for some pmf files, try again after computing volumes.
• On systems with AMD graphic cards, if you experience stability issues when
displaying the model, toggle off the ‘Enable optimized rendering’ option in the
Graphics tab of the Preferences panel (to post this panel, select File > Preferences
from the menu).
ProCAST Solver 2015 Updates

Main Updates
• The dimensionless Niyama porosity model has been introduced and allows for
micro-porosity calculations, which take into account the alloy properties.
• The interpenetrating mesh algorithm has been redesigned to lower the mesh
dependency and better model shot piston, open mold foaming, etc.
• A second generation of the Advanced Porosity Module APM (beta version) has
been developed for shrinkage and gas porosity defects, taking into account the
liquid pressure. Performance in terms of memory requirement and solving time
(DMP version) has been significantly improved. This version is restricted to
2 processors.
Improved User-Defined Functions Capabilities

• User-defined functions func_sprayhtc() and func_spraytemp() have been
implemented to handle complex spraying effects.
Other Updates
• Shrinkage porosity algorithm has been reviewed and calculation time has been
reduced compared to previous versions.
• The oxidation algorithm has been enhanced and the β parameter can be now
modified (growth coefficient to model oxygen pick up at free surface) in the
inclusion equation.
Release Notes
Visual-Cast
• Stability, solution quality and robustness for FLOW at Pool model switch and in the
mushy zone have been improved.
• For Optimization, capabilities for more advanced output criterion (new results and
computation zone) have been extended.
• JUNCTION criteria, such as “oxides”, “front tracking”, “material age” and “flow
length “can now be used independently for Optimization outputs criteria. The size
of files generated through the usage of CAFE coupling has been significantly
reduced.
Limitations
• For pressure inlet driven cases, like Lost Foam, it is recommended to reduce the
convergence parameter PCONVTOL to 1e-04 for better convergence.
• New fluid flow solver does not yet support the cases with Accordion.
• For ductile iron, it is advised to ignore P and S components that could prevent
computation of ferrite and pearlite phases.
Release Notes
Visual-Cast
VISUAL-MESH (CAST)
CAD Import
• New CAD formats supported: AutoCAD files with *.dxf, and *.dwg extensions
are supported (versions 2.5 to 2014 on Windows platforms only).
• STL Import Improved: Nodes are fused within parts at the time of import.
Change / Convert Length Units
The Length Units dialog has been modified

to provide additional information of length
unit conversion.
Release Notes
Visual-Mesh (Cast)
Surface Selection
When CAD parts are displayed in feature-line mode, surfaces can be selected by
picking on the internal feature lines:
Surface Repair
• For ‘Delete Edges’ function, a, entity selector is enabled to select multiple edges
using rectangle pick.
Release Notes
Visual-Mesh (Cast)
Volume Computation
• More meaningful statuses of volume representation are provided in Compute
volume dialogs. The Create-Cavities option is also provided in this message box
itself now:
Release Notes
Visual-Mesh (Cast)
• The new Compute Volumes at Model Import Stage option has been added to control
volume computation at the time of model import. This is required for STL meshes
used in finite difference analysis:
Topo Mesh
• For ‘Delete Edges’ function, an entity selector is enabled to select multiple edges
using rectangle pick.
• New Unfix Mesh option: If the mesh on some surfaces is fixed, it can be unfixed
with this option.
Release Notes
Visual-Mesh (Cast)
Check Surface Mesh

The Bad Quality option is disabled for the Coarse Mesh scheme to support STL meshes
used in finite difference analysis (like QuikCAST simulations). It is not important to
have high quality elements, since the STL is only used to define volumes.
3D Mesh Quality Checks

• Computation performance has been improved.
Limitations
• Due to up gradation of Interop to R25 to support new CAD formats, there may be
regression in STEP and ProE files import.
Release Notes
Visual-Mesh (Cast)
VISUAL-VIEWER (CAST)
CAFE Histogram
Description
This tool plots the histogram of different stereological parameters like grain size, grain
orientation and shape factor. The analysis can be done only on one section cut. If there
is more than one section cut, only the latest visible section cut will be considered. The
menu entry will be disabled if there is no section cut or if the result applied is not of
CAFE.
Options
• Grain Orientation Deviation: This is the deviation of grain with respect to the defined
orientation axis.
• Grain Size: This is the cut area of grain, sliced by the section cut plane.
• Shape Factor: This is an indicator of the shape of the grain. The value ~1 means the
grain is close to a disk.
Release Notes
Visual-Viewer (Cast)
CAFE Statistics
This tool displays the statistics of grain size, orientation as well as grain stereological
information. The analysis can be done only on one section cut. If there is more than one
section cut, only the latest visible section cut will be considered. The menu entry will be
disabled if there is no section cut or if the result applied is not of CAFE.
CAFE Pole Figure

This tool displays the stereographic representation of grain orientation with respect to a
[001] axis. The analysis can be done only on one section cut. If there is more than one
section cut, only the latest visible section cut will be considered. The menu entry will be
disabled if there is no section cut or if the result applied is not of CAFE.
Release Notes
Fixed Issues
• Changing the context from Visual-Viewer Cast to Visual-Cast did not load the
corresponding .pmf file in the case of a QuikCAST set-up. This issue has been
fixed.
• QuikCAST tilt models were not animating properly. This issue has been fixed.
Known Issues
• Updating APM results during the solver run may sometimes crash the application.
• If you select View > Home Page when a model is active, the Contour dialog does not
disappear as expected. If you select a different result, when the model is displayed,
the contour colors are not correct. It is recommended to select the result again or
post the Spectrum dialog to avoid this issue.
• If more than one Principal stress is selected for display as vectors, the Principal
stress maximum value will not be displayed properly in the legend.
• If units are changed in the cut-off mode, contours will not be displayed properly. It
is recommended to change units in the snapshot mode and then switch to the cut-off
mode.
• When copying and pasting models from one window or page to another, the image
may not be displayed as expected. However the model is displayed properly by
pressing 'F', i.e. fitting the model within the window.
• Sometimes, during CAFE results display, the model is not refreshed. It is
recommended to click on the model window and rotate.
• In DEFORM export, coincident and equivalent interfaces are detected using
<prefix>ff.unf file. If this file is not present, then the exported file will not be
proper. It is then recommended to export only the final single part to be imported
into DEFORM rather than the whole model, as DEFORM manages interfaces
differently.
• In case of Profile plotting for dynamic models like MILE, the profile created at one
step will give incorrect result if plotted during another step.
Limitations
• The template does not support calculated particles, free surface / point XY-plotting.
• The Entity Selector may become inactive in some situations. To activate it again,
activate the model window and press the Escape key.
• The volume of porosity computation is linked to the mesh size; consequently, this is
an approximated value.
• For QuikCAST models, tilt and explode cannot be applied simultaneously.
Release Notes
• Exporting the evolution curves plotted does not work as expected: if the curve
names are not present in the Page/File View tab, exporting two or more curves by
pressing the ‘Control’ key and right-clicking will give an error.
• Stress tensors are not displayed on mold.
• To view the solver calculation status in the "Calculation Monitoring" GUI, the
solver path must contain the solver version number (ex. 2013.5 or 2013.0, etc.)
• Misrun is caused by a combined effect of viscosity and permeability. The risk
indicator is not applicable to thixo casting since the metal at inlet is already in the
mushy zone.
• Unit conversion is not supported for "Temperature gradient" results. It is always
displayed in K/cm.
• The model path should have write permission.
• Since the Inclusion Particle Tracking tool acts in post-processing mode, it relies on
the frequency of the result storage, controlled by the run parameter VFREQ. With
high values of VFREQ, there may be too little information to displace the trace.
Therefore, the results may not be very accurate, with the trace leaving the alloy
domain. In that case it is advised to reduce VFREQ.
Release Notes
CORE DUMP TRACKER

You can register any crash that occurs while you are working with Visual-Environment
through the Core Dump Tracker utility. This utility is available only on Windows
systems.
Whenever the application crashes, you will see the following dialog box:
• Click Send Error Report to send the report and close both the dialog box and the
application.
• Click Don’t Send to close the dialog box and the application without sending a
report.
Release Notes
Core Dump Tracker
• Click View Report Details… to check details of the report that will be sent. You will
see the following dialog listing of the files that will be sent:
• By default, the check box to send additional files is OFF and only the files marked
with a ‘*’ against their name will be sent.
To send the additional files, check the box ON.
By default, the session file is not sent.
You can also set the following variables in the VisualEnvrc.bat file residing in your
‘Site’ folder to customize the settings:
• If you wish to send your session file, add the following line:
set VHOST_COREDUMPTRACKERFILES_ENABLE=1
• If you do not want to use the Core Dump Tracker, add the following line:
set VHOST_COREDUMPTRACKER_ENABLE=0
We would appreciate your help to improve your experience with Visual-Environment by

sending us a report through this utility. We assure you that the information you send us
will be used only to solve the reported problem and confidentiality of the information
will be fully maintained.
Release Notes
Core Dump Tracker
INSTALLATION GUIDE
SOFTWARE INSTALLATION ON WINDOWS
Installing the Software
Insert the DVD into the disc drive and follow the procedure described below depending
on if autorun is enabled on your computer or not.
Autorun is enabled on your computer

The ProCAST installation should start automatically.
The InstallShield Wizard dialog box is displayed and then you should simply follow the
instructions.
Autorun is disabled on your computer

1. Open a Windows Explorer window and click on your DVD drive icon.
2. Double-click on the CastSetup.exe file, located in the root directory of the
DVD, to start the software installation.
The InstallShield Wizard dialog box is displayed and then you should simply follow the
instructions.
When the software installation is completed, the ProCAST and Visual-Environment
products will be available in the Start/Programs/ESI Group menu or in the ESI
Group icon folder on the desktop.
Installation Guide
Software Installation on Windows
Installing the License

Before starting the license installation you should obtain a valid license file. Note that
the ProCAST software is version protected and compiled with FLEXnet
version 11.11.1. License files delivered for the previous ProCAST versions are not valid
with this version of the software, except if your license does already contain the 2015
label.
It is highly recommended to upgrade an existing license server with the FLEXnet
Licensing Utilities v11.11.1.1 which is delivered in this installation.
Retrieving System Information Needed

System information must be retrieved before you can request your FLEXnet license
files if required:
1. For each PC machine that will be running ProCAST, execute
c:\flexlm\lmtools.exe
2. Select the System Settings tab
3. Send all the information on the left part (Hostid Settings) to your local ESI
support representative with the Save HOSTID Info to file option.
Once you have received your(s) license file(s), it/they must be moved to the appropriate
directory c:\flexlm on each machine with the file name pam_lmd.lic.
Installation Guide
Starting the FLEXnet License Server

The FLEXnet license server installation must be done with administrator privileges.
After the ProCAST installation is completed, your pam_lmd.lic file must be moved
to the appropriate directory, updated and the FLEXnet license server started.
To move and update the license file:
1. Move pam_lmd.lic to the c:\flexlm directory.
2. Using any usual text editor, edit the pam_lmd.lic file and adapt the
SERVER/VENDOR lines if necessary.
To start the license server:
1. Execute c:\flexlm\lmtools.exe
2. Select the Service/License file tab and select Configuration using Services.
Installation Guide
3. Select the Configure Services tab and adjust parameters as shown below:
4. Click the Save Service button.

5. Select the Start/Stop/Reread tab and click the Start Server button:
After completing these installation steps, you may start using ProCAST.
Additional specific FLEXnet documentation is also provided in c:\flexlm.
Installation Guide
SOFTWARE INSTALLATION ON LINUX

Overview
To install the ProCAST product on Linux platforms, two installation procedures are
available:
paminst-gui.sh GUI script
paminst.sh command line script
Both procedures perform the following tasks:
1. Software installation:
· Copy from the CD-ROM all the software files to the chosen location.
2. License management:
· Install the license file.
· Start the license daemons lmgrd and pam_lmd if needed.
· Install the license daemon startup scripts*.
3. Customization:
· Set up the ESI Group software environment for each current user.
Tasks 2 and 3 can be performed later if you do not want to do them immediately.
After the installation, the files installed on the hard disk are organized in a directory tree
as shown below:
Head Directory
this is referenced as PAMHOME
Installation Scripts...
MODULE 1 MODULE 2 Examples LICENSES DOC

Executables, other files... Executables, other files... Examples files, test cases... License file Electronic documentation
Version1_COMMON Version1_platformOS1 Version1_platformOS2 Version2_platformOS1 platformOS1 platformOS2

Ressource files Executables Executables Executables Deamon and tool files Deamon and tool files
*
Sufficient privileges may be required by the system during the installation of ESI Software products.
Although no system library is updated in the process, sufficient privileges will be needed to mount the
CD-ROM and install the boot files to start the license server.
Installation Guide
Software Installation on Linux
CD-ROM Mounting Instructions

1. Insert the CD-ROM into the CD-ROM drive.
2. Follow the CD mounting and dismounting instructions in the table below.
When the installation is done, do not forget to quit the /cdrom directory before ejecting
the CD-ROM from the drive.
PLATFORM MOUNTING SPECIFIC INSTRUCTIONS DISMOUNTING
PC Windows Automatic - -
PC Linux Automatic - eject
# symbol is the SCSI Id number of the CD-ROM drive
Device names in italics are site-dependent
System Requirement
The installation through the Graphical User Interface is available on Linux. In order to
use the graphical installation, you need an X compliant window system available on
your display. You must position the DISPLAY environment variable for display on the
current screen, and if necessary allow this display using an appropriate xhost command
on the display host. You also need about 15 Mb of free space in /tmp, in order to store
graphical tools temporarily.
Installing the Software

Proceed as follows for the graphical software installation:
1. To start the graphical software installation script, go to the /cdrom directory
then type the following command:
./INSTALL.SH
2. To complete the installation, follow the instructions displayed in blue color in
the dialog boxes presented by the installation tool.
Installation Guide
After the graphical tools are loaded in /tmp, the main dialog box window
appears:
Main Dialog Box

3. Click the Install software button. It will highlight the Next button to continue.
4. Click the Next button to continue the software installation.
Installation Guide
Installation Directory Dialog Box

5. In the displayed dialog box, specify the installation directory.
By default, the text field of the installation directory is filled with the previous
pathname of ESI Group software installation directory if any.
To select a new software installation location on the system, you can either:
• Click and fill in the text field with a valid pathname directory (read,
write, execute permissions are required).
• Click the Browse button to select another software installation location
(see Directory Selector dialog box for using it).
6. Click the Next button when you are satisfied with the software installation
directory selected.
7. Select all the package(s) you wish to download on the system by clicking on the
toggle(s).
Installation Guide
Package Selection Dialog Box

8. Click the Next button to continue. Note that, if not already done, the
flexnet_v11.11.1 package should also be installed.
A scrolled window is displayed showing the downloading of files.
When the downloading is finished, the Close button will be highlighted.
9. Click Close to continue.
Installation Guide
The main dialog box window appears again to perform the next steps, the license
installation and/or Customization of the software environment.
• Click the Exit button if you wish to perform the License installation and software
customization later.
• Click the License management button to install the license. A license file is
needed to perform this task. For further details, please see the Installing the
license section.
• Click the Define environment button to customize the software environment. For
further details, please see the Customizing the Installation section.
Installation Guide
Installing the License

Before starting the license installation you should copy the new or updated FLEXnet
license file provided by ESI Group representatives in the following directory:
PAMHOME/licenses with the filename pam_lmd.temp.
Note that the ProCAST software is version protected and compiled with FLEXnet
version 11.11.1. License files delivered for the previous ProCAST versions are not valid
with this version of the software, except if your license does already contain the 2015
label.
It is highly recommended to upgrade any existing license server with the latest version
of the FLEXnet Licensing Utilities v11.11.1.1 which comes with this installation.
The installation of the license should be performed on the system where the license
server will run:
1. To start the license installation script, go to the software installation directory
and type one of the following commands:
./paminst-gui.sh lic
or
./paminst-gui.sh install_lic
After the graphical tools are loaded in /tmp, the following assistant window
appears:
Installation Guide
2. Follow the instructions displayed in blue color.

3. Click the Get host id. button to get the information (Operating System,
hostname, hostid) of the system needed for license server installation (floating
license) or standalone license (node-locked license). It will display the following
window:
Important Remark on Linux i686 or x86_64 based Distributions

The FLEXnet Toolkit can only run on LSB3 (Linux Standard BaseTM) compliant Linux
distributions.
The “LSB3 OS Compliant” detail must display “Yes”, otherwise your Linux distribution
cannot run a license server with this latest version of the FLEXnet Toolkit.
Check that one of the following packages is installed on the station:
• RedHat Based Operating Systems:
For RedHat, CentOS, Oracle Linux, Fedora …: package redhat-lsb
How to check installation: rpm -q redhat-lsb
How to install it (as root or with sudo): yum install redhat-lsb
• SUSE Based Operating Systems:
For SUSE Entreprise, openSUSE …: package lsb
How to check installation: rpm -q lsb
How to install it (as root or with sudo): yast2 -i lsb
• Debian Based Operating Systems:
For Debian, Ubuntu …: package lsb
How to check installation: dpkg-query -l lsb
How to install it (as root or with sudo): apt-get install lsb
Installation Guide
By default, the Install licenses directory under directory: text field is filled with
the pathname of the previous software installation directory.
4. Click the Browse button to redefine the pathname of the software installation
directory.
Note:
· The specified directory in the text field should contain a licenses subdirectory
with write permission to highlight the Next button.
5. Click the Next button when the installation directory pathname is selected. The
license file is installed in the right location and the following dialog box
appears:
6. Click the Get another license file button to select a new license file.
Installation Guide
7. Click the OK button to find the new license file on the local disk. A new file
browser window appears:
By default the file filter is set to find the PAM license file.
8. Select the new license file and click the Open button to validate the selection.
A small window pops up displaying the checking result of the selected license
file with the host id.
The dialog box of license file selection will be displayed again and filled with
information corresponding to the selected license file.
Installation Guide
9. Click Apply changes to new file and then Save new file as current.
The new license file is installed and the Next button is activated to continue.
10. Click the Next button to start the license daemons.
11. Click the Start daemon now as current user button to start the daemon.
Additional specific FLEXnet documentation is also provided with the software on
the installation CD-ROM.
Installation Guide
Customizing the Installation

The ESI Group software installation script paminst.sh can be used for customizing
the installation.
This customization is done with pamcust.sh which can also be used separately. To
perform the customization separately:
1. Log in on the machine on which you want to perform the customizations.
2. Change directory to the $PAMHOME directory where the installation has been
done.
3. Type ./pamcust.sh and follow the instructions.
The customization script creates definitions to allow access to the ProCAST executables
and configuration files for all users or for selected users, depending on the method
selected. The software configuration is defined in the following files:
• psi.Cenv for csh and derivatives,
• psi.Kenv for ksh and derivatives,
• Psi.Baenv for bash
Note that sh is not supported, due to its lack of functionality necessary for ESI Group
products. We recommend sh users to migrate to ksh which preserves sh syntax and
habits.
Installation Guide
The customization procedure will automatically update the .cshrc, .profile or

.bash_profile files accordingly, as shown below:
C Shell - .cshrc file ### ESI-Group begin ###

#
# ESI-Group Software environment
#
setenv PAMHOME /home/ppg/ESIGroup
setenv PAMENV $PAMHOME/env-‘uname’
if ( -r $PAMENV/psi.Cenv ) then
source $PAMENV/psi.Cenv
endif
### ESI-Group end ###
Korn Shell - .profile ### ESI-Group begin ###

#
#
PAMHOME=/home/ppg/ESIGroup; export PAMHOME
PAMENV=$PAMHOME/env-‘uname’; export PAMENV
if [ -r $PAMENV/psi.Cenv ]; then
. $PAMENV/psi.Kenv
fi
ENV=${ENV:””}
if [ -z “$ENV” ]; then
ENV=$HOME/.kshrc; export ENV
fi
Bourne Again Shell - ### ESI-Group begin ###

.bash_profile #
#
PAMHOME=/home/ppg/ESIGroup; export PAMHOME
PAMENV=$PAMHOME/env-‘uname’; export PAMENV
if [ -r $PAMENV/psi.Baenv ]; then
. $PAMENV/psi.Baenv
fi
if [ -z “$BASH_ENV” ]; then
BASH_ENV=$HOME/.bashrc; export BASH_ENV
fi
The same procedure must be repeated for the customization of each candidate user.
Installation Guide
GETTING STARTED
Starting the Software
For Windows Platforms
When the software is installed on a Windows platform, a file folder named ESI Group is
automatically created on the computer desktop. Inside this folder, "ProCAST 2015.0"
with “Visual-Cast 10.7” icon is present. A double-click on this icon will automatically
start the software manager, respectively the new environment, and give access to the
different product modules.
For Linux Platforms

The installation procedure includes a customization procedure. The customization script
creates definitions to allow access to the different executables and configuration files
for all users or for selected users, depending on the method chosen.
After a complete and successful product installation, necessary environment variables
and aliases are automatically defined to start different product modules. Type the
following commands for a direct access:
• datacast and procast/procastcafe/procastapm for the solvers,
• vcast for the pre-processor Visual-Cast.
Note that access to previous versions of ProCAST is possible with modified aliases. For
instance, type procast145 / vcast100 for ProCAST 2014.5.
Online Product Documentation

Online product documentation is available for most ProCAST features. One manual is
provided with the standard installation: the ProCAST User’s Guide. This Manual
provides extensive information to guide you through the different modules of ProCAST,
to explain the use of different software features as well as to give technical information
on models and algorithms.
Refer to the User Manual and in particular to the What’s New / Version 2015 section for
detailed information on all new and improved product features.
Installation Guide
Getting Started
myESI CUSTOMER PORTAL

ESI Group launched its customer portal, myESI. The primary goal is to provide you
with valuable content.
myESI’s dedicated Casting Solution (ProCAST, QuikCAST, Visual-Environment)
content is accessible once you login to myesi.esi-group.com.
With your account, you can benefit from Tips & Tricks and explore worldwide trainings
which are available in the online training schedule. You can also access the
“Download” section with technical documentation, including product manuals, release
notes, specific tutorial guides and add-ons.
Under Downloads, you can access ESI’s new license-free and browser-based tool called
ESI-Player, to visualize ESI result files.
The content provided on the portal is continuously updated.
If you do not already have a myESI account, join by clicking on Create new account to
get started!
Installation Guide
myESI Customer Portal
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RELEASE NOTES &

© 2015 ESI Group. All rights reserved.

ESI GROUP CASTING TEAM

Getting Started -------------------------------------------------------------------------- 42

Grid Definition Support

• The following options are available:

· Modify: Allows for modification of a grid line location.

Piston Process Condition

• A new Graphical User Interface (GUI) is developed to define piston process

Implicit Mold Process Condition

• A new GUI is developed to define Implicit mold process condition.

Cooling Process Condition

Contact Resistance Process Condition

• The Contact resistance process condition is supported inside interface folder.

CCT and TTT Diagram Display

• CCT / TTT diagrams are now supported in material editor.

ProCAST Solver 2015 Updates

Improved User-Defined Functions Capabilities

Change / Convert Length Units

The Length Units dialog has been modified

Check Surface Mesh

3D Mesh Quality Checks

CAFE Pole Figure

CORE DUMP TRACKER

We would appreciate your help to improve your experience with Visual-Environment by

Autorun is enabled on your computer

Autorun is disabled on your computer

Installing the License

Retrieving System Information Needed

Starting the FLEXnet License Server

4. Click the Save Service button.

SOFTWARE INSTALLATION ON LINUX

MODULE 1 MODULE 2 Examples LICENSES DOC

Version1_COMMON Version1_platformOS1 Version1_platformOS2 Version2_platformOS1 platformOS1 platformOS2

CD-ROM Mounting Instructions

Installing the Software

Main Dialog Box

Installation Directory Dialog Box

Package Selection Dialog Box

Installing the License

2. Follow the instructions displayed in blue color.

Important Remark on Linux i686 or x86_64 based Distributions

Customizing the Installation

The customization procedure will automatically update the .cshrc, .profile or

C Shell - .cshrc file ### ESI-Group begin ###

Korn Shell - .profile ### ESI-Group begin ###

Bourne Again Shell - ### ESI-Group begin ###

For Linux Platforms

Online Product Documentation

myESI CUSTOMER PORTAL

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