NovaFlow&Solid CV GRAVITY CASTING & HIGH PRESSURE DIE CASTING
A capable casting process simulation package developed for most categories of foundry applications.
www.novacast.se
GRAVITY CASTING NovaFlow & Solid CV is a mould filling and solidification simulation package based on advanced fluid flow and heat transfer theories. New meshing technology and new advanced numeric models, Control Volume Meshing (CVM) makes it the most efficient simulation package on the market. NovaFlow & Solid CV requires less than one hour to set up a complete simulation including start-up, meshing and running. The resulting simulation will be extremely accurate in accordance with your 3D drawings.
Simulations Most of the casting methods on the market can be simulated such as gravity sand casting, gravity permanent mould, low pressure die casting, high pressure die casting, lost wax method, tilt pouring and lost foam process. Commercial alloys can be simulated such as grey- and ductile iron, steel, aluminium alloys, copper-, zinc- and magnesium-based alloys, super alloys, all types of mould and core materials that exist on the market and exothermic materials as well as chills. Simulations visualise the consequences of a certain design of gating systems and moulds. Casting defects, such as oxide inclusions due to excessive turbulence, cold-shuts, shrinkage cavities and slag inclusions, can be avoided by optimising the design of the gating and venting system.
CVM technology CVM technology allows the surface of the 3D model to control the shape of the mesh elements on the border of the casting. This creates cubic elements inside the casting and border cells on the boundary of the casting.
Advantages CVM technology has the following advantages in comparison with FDM/FEM methods: • For most castings, simulation time is reduced to around 10 percent with the same or improved accuracy (FDM) • A higher accuracy in simulation, due to perfect description of the 3D model. All sections are correct in size (FDM) • Less cells are needed to define the casting geometry which ensures faster simulations and smaller result files (FDM) • The meshing process is completely automatic and only takes seconds (FEM) • Advanced calculations are enabled, such as gas flow, contact task (stress) or full mould process (FDM)
Unique functionalities In addition NovaFlow & Solid CV has the following unique functionalities: • Option to use the ATAS thermal analysis system for updating the alloy database in NovaFlow & Solid CV, with actual data based on poured samples. The effect of graphite expansion can be accurately modelled • A formula function for creating your own criteria, for example shrinkage prediction. This function also enables the calculation of Dendrite Arm Spacing (DAS) and matrix • With the particle tracer function, users can more accurately simulate flow behaviour and also induce slag particles into the melt for tracing • A thermal modulus calculation with feeder design. Size of feeder and feeder neck is calculated. • Gas calculation which enables backpressure and vacuum permeability • Dual mesh function. Use different mesh for filling and solidification. • Gating calculation
3D Import
Simulation
• Import of binary and ASCII STL files and STEP files • Import of cooling channels and filter • STL fixing • Boolean functions • Extension functions • Positioning functions • Creation of shell
• Fastest and most accurate simulation package on the market • Multiple processor support • The easiest package for setting up and rerunning a simulation • Calculation of velocity, pressure, temperature, liquid phase, local solidification time, wall contact, air contact, air pressure and air entrapment • Macro shrinkage prediction with the shrinkage criteria and micro shrinkage prediction with the Niyama criteria • Mesh size is limited to RAM.
Characteristics • Includes advanced database based on constitution diagrams • Accounts for gravity during simulation • Calculates air gap formation or heat transfer coefficient • Cooling and heating channels (permanent mould) • Cycling with several setting (permanent mould) • Saving mould temperature from a rough simulation into a fine-meshed simulation (permanent mould) • Several filling alternatives, including bottom-pouring ladles, ladle pouring over lip and low pressure die casting, multi stopper ladles • Particle trace function (tracking of slag inclusions) with flow length and age • Auto-simulation, running multiple simulations in a batch • Sensors measuring velocity, pressure, temperature, liquid phase and cooling rate at a certain point • Flow meter measuring the efficiency of an ingate • 2D and 3D velocity vectors • Pouring of multiple alloys for bimetallic cast
Results presentation • Powerful browsing and slicing in x, y and z directions • Built-in animation functions for presentation of results, creation of AVI and real time AVI movie files as well as WMV • Two or more simulations can be viewed simultaneously in the browser • Printing facility in all modules • Possibility to save simulations in BMP or JPEG formats in each module • Automatic report generator in doc-format • Automatic movie creation
Hardware Recommendations • PC with QUAD Core (4) or 6 or 8 core processors (Multiple processor support) • Highly recommended: Intel Xeon or Intel Core i7, 3.3 GHz and higher • Microsoft Windows 7 or 8, 64-bit • Recommended: 16 GB RAM • 200 GB free hard disk space • Highly recommended: Solid state drive 128GB as primary disc where simulation should run and be stored during simulation, normal HDD 1TB for storage after simulation as secondary disc • Graphics card: NVidia 2GB and higher • 3D mouse for rotation, move and zoom. System supports 3D connexion Space navigator
HIGH PRESSURE DIE CASTING NovaFlow & Solid CV is a mould filling and solidification simulation package based on advanced fluid flow and heat transfer theories.
New meshing technology and new advanced numeric models, Control Volume Meshing (CVM) make it the most efficient simulation package on the market. NovaFlow & Solid CV requires less than one hour to set up a complete simulation including start-up, meshing and running. The resulting simulation will be extremely accurate in accordance with your 3D drawings.
Simulations Most of the casting methods on the market can be simulated such as gravity sand casting, gravity permanent mould, low pressure die casting, high pressure die casting, lost wax method, tilt pouring and lost foam process. Commercial alloys can be simulated such as grey- and ductile iron, steel, aluminium alloys, copper-, zinc- and magnesium-based alloys, super alloys, all types of mould and core materials that exist on the market and exothermic materials as well as chills. Simulations visualise the consequences of a certain design of gating systems and moulds. Casting defects, such as oxide inclusions due to excessive turbulence, cold-shuts, shrinkage cavities and slag inclusions, can be avoided by optimising the design of the gating and venting system.
CVM technology CVM technology allows the surface of the 3D model to control the shape of the mesh elements on the border of the casting. This creates cubic elements inside the casting and border cells on the boundary of the casting.
Advantages CVM technology has the following advantages in comparison with FDM/FEM methods: • For most castings, simulation time is reduced to around 10 percent with the same or improved accuracy (FDM) • A higher accuracy in simulation, due to perfect description of the 3D model. All sections are correct in size (FDM) • Less cells are needed to define the casting geometry which ensures faster simulations and smaller result files (FDM) • The meshing process is completely automatic and only takes seconds (FEM) • Advanced calculations are enabled, such as gas flow, contact task (stress) or full mould process (FDM)
Unique functionalities In addition NovaFlow & Solid CV has the following unique functionalities: • Option to use the ATAS thermal analysis system for updating the alloy database in NovaFlow & Solid CV, with actual data based on poured samples. The effect of graphite expansion can be accurately modelled • A formula function for creating your own criteria, for example shrinkage prediction. This function also enables the calculation of Dendrite Arm Spacing (DAS) and matrix • With the particle tracer function, users can more accurately simulate flow behaviour and also induce slag particles into the melt for tracing • Gas calculation which enables back pressure and vacuum permeability • Use of moveable piston in chamber in order to simulate the filling in first phase • Dual mesh function. Use different mesh for filling and solidification
3D Import
Simulation
• Import of binary and ASCII STL files and STEP files • Import of cooling channels and filter • STL fixing • Boolean functions • Extension functions • Positioning functions
• Fastest and most accurate simulation package on the market • Multiple processor support • The easiest package for setting up and rerunning a simulation • Calculation of velocity, pressure, temperature, liquid phase, local solidification time, wall contact, air contact, air pressure and air entrapment • Macro shrinkage prediction with the shrinkage criteria and micro shrinkage prediction with the Niyama criteria • Mesh size is limited to RAM.
Characteristics • Includes advanced database based on constitution diagrams • Accounts for gravity during simulation • Calculates air gap formation or heat transfer coefficient • Import cooling and heating channels • Cycling simulation with multiple cooling phases • Saving mould temperature from a rough meshed cycling simulation into a fine-meshed flow & solid simulation. Enables extremely fast cycling simulations • Velocity trigger function (set in the 1st and 2nd phase) • Trigger filling time. Setting velocity in 1st phase and filling time in 2nd phase • Piston position controlled velocity with moveable piston • 1st, 2nd and 3rd phase, i.e. the compression phase, can be simulated. Accurate shrinkage predictions can be obtained. • Vents, for calculating air bubbles • Particle trace function (tracking of slag inclusions) with flow length and age • Sensors measuring velocity, pressure, temperature, liquid phase and cooling rate at a certain point • Flow meter measuring the efficiency of an ingate • 2D and 3D velocity vectors
Results presentation • Powerful browsing and slicing in x, y and z directions • Built-in animation functions for presentation of results, creation of AVI and real time AVI movie files as well as WMV • Two or more simulations can be viewed simultaneously in the browser • Printing facility in all modules • Possibility to save simulations in BMP or JPEG formats in each module • Automatic report generator in doc-format
Hardware Recommendations • PC with QUAD Core (4) or 6 or 8 core processors (Multiple processor support) • Highly recommended: Intel Xeon or Intel Core i7, 3.3 GHz and higher • Microsoft Windows 7 or 8, 64-bit • Recommended: 16 GB RAM • 200 GB free hard disk space • Highly recommended: Solid state drive 128GB as primary disc where simulation should run and be stored during simulation, normal HDD 1TB for storage after simulation as secondary disc • Graphics card: NVidia 2GB and higher • 3D mouse for rotation, move and zoom. System supports 3D connexion Space navigator
NovaFlow&Solid CV Faster and more accurate simulations
NovaCast Systems AB Soft Center 372 25 Ronneby SWEDEN info@novacast.se +46 457 46 58 00 www.novacast.se