U S E R GU I D E

NovaFlow & Solid CV 4.6

Quick user guide

Content

1. Introduction ..................................................................................................................................... 3
2. Default settings ................................................................................................................................ 4
3. Import 3D files ................................................................................................................................ 8
4. Simulation setup .............................................................................................................................. 9
5. Simulation modules ....................................................................................................................... 19
6. Browse the results ......................................................................................................................... 21
7. Contact .......................................................................................................................................... 24

2013-05-30 © Novacast Systems AB

 INTRODUCTION
1. INTRODUCTION

The purpose of this quick user guide is to show the basic procedure for using the software.
This guide uses our test file DemoNS98 as an example.

The model is usually first constructed in a CAD environment and then incorporated in
NovaFlow & Solid as an STL-file.

The Foundry Center is a new navigation panel with centralized functionality such as
default settings, database, navigation in the program, remote support and license updating.

To customize the Foundry Center, choose “Tools” and “Show/hide command…” Tick the
modules that you wish to see in the menu bar to the right.

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 DEFAULT SETTINGS
2. DEFAULT SETTINGS

For efficient use of the program there is a section in NovaFlow & Solid CV called “Default
settings”, which will open the “System property” window where the program behavior can
be changed to better suit the process used.

In the System property menu it is possible to select language, set measure units (Metric
System or Imperial System), choose “Autoload last project”, set Projects location etc.

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 DEFAULT SETTINGS
Number of threads to be used must be set under “Multithreading”. (The system
automatically detects number of processors but selection is made manually)

Set “Autoload last project” to “True” to automatically load the active file/project into the
next module. It is also possible to set if the viewing should be default as section, isometric
or transparency.

NovaFlow&Solid CV can pick info from different places by setting paths. Paths to choose
are: “Material database path”.

Note: Simulation results should not point to a server because of the size of generated files.

By default the program is set to create a mesh consisting of 500 000 cells. This can be
changed depending on dimensions of casting and type of method. Default values for
minimal mould thickness around the casting are also set here. For larger castings (> 1000
kg) it should be 50–100 mm.

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 DEFAULT SETTINGS
In Autosave “Data for saving” it is possible to select which Process and Result fields
should be saved during simulation.

In Autosave “Criteria for saving” the interval by which the simulation results should be
saved is set. Every 1 % is normal for mould filling and for solidification every 1 %. Open
“Autosave” and click on the criteria to be changed. Click on the “…” to the right. This
opens a new window where it is possible to change the intervals for the chosen criteria.
Confirm changes by clicking “OK”.

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 DEFAULT SETTINGS
NovaFlow&Solid provides a comprehensive database of various cast alloys. However,
viewing the database can be minimized. The principle is to set typical materials as default
with realistic temperatures and tick off all alloys that are not used.

Alloys can also be added/modified by the user to better fit his process.

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 3D IMPORT
3. IMPORT 3D FILES

Note: Saving is not possible in the demo version. Only existing 3D models can be used.
Contact Novacast for additional 3D models.
The following files can be imported into NovaFlow&Solid CV:
.stl
.stp
.step
.flt
.cvg

Open the “Import 3D files” module. Choose “File/Open” or click . Choose

“DemoNS98.stl” in the file browser. The model below appears. The orientation of the part is
however incorrect, therefore the rotation function must be used. Press the rotation button
and rotate by pressing the left mouse button pointing at the part.

Make a rough positioning using the rotation function (1), then click on tab “Rotate XYZ”
(2) and press “Align X”, “Align Y” and “Align Z” (3). All angles should now be in 90
degrees (4). To set this as default for the casting, press “Fix orientation” in the same
toolbar. Below picture shows correct orientation for the casting.

(1)

(4)
(2) (3)

Save the casting file in this position by clicking on (replace the existing one). Saving
stl-files in the demo version is not possible. This can only be done in the full version. Close
this module and proceed to “Initial Settings”.

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 SIMULATION SETUP
4. SIMULATION SETUP

Open the “Simulation setup” module.

Files created and assembled in “Import 3D files” are imported to “Simulation setup”. If
the AutoLoad function is ticked in the Default Settings the model saved in Import 3D
files will load automatically. (Not possible in the demo version.)

If the file does not open automatically, choose “File/Open” or click . Choose
“DemoNS98” in the file browser.

This model appears.

All different coloured solids are created separately (CAD) and assembled in “Import 3D
files”. Each solid can be given separate properties. Casting should always be the first
colour (light blue). Note that for example a core should be a different colour (solid object
= stl-file).

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 SIMULATION SETUP
4.1. Set the mesh parameters

Choose Build mesh or click . The “Parameters of mesh” window will appear. These
parameters must be set for the computational calculation. The model is then divided into
small “cubes” combined with border cells resulting in a mathematical approximation
exactly like the original model. The size of the cells is no longer so critical, therefore you
can use rather large cells. Choose “Number of cells” tab. Enter 10 in the “Dimension of
cell, mm”. Click “Apply”. You will now see how many metal cells your settings have
created. Pulling the handle or typing a new value in the window changes the number of
cells.

Use the default mesh settings for ~500 000 cell count as a start.

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 SIMULATION SETUP
In the “Mould thickness” tab you can adjust the mould thickness around the casting.
Default is 25 mm. Increase this value if your casting is large. The new values can be set
in default settings.

Leave the menu bar by clicking on Ok. Choose “Output Isometric”

The casting described by CV mesh should now be shown like this:

Switch the viewing back to “Output Section” on the same menu bar.

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 SIMULATION SETUP
4.2. How to view different cross-
cross-sections
This is how to view cross sections in the model.

Choose “Change section”.

The basics are: click the desired cross-sectional plane (side of the surrounding box), drag
the cross sectional selection (blue) to the desired cut, right-click.

a) Click the d) The cross-

xz-plane. section can
(Do not now be
hold the viewed.
left-
left-click
mouse
button
down)

b) Drag the e) Box-zoom;

cut to the Click and
desired choose a
position. section, click
on the left
mouse-button.

c) Right- f) To view the

click to grid, click
position the or choose
cross “View” and
sectional “Grid on/off”.
selection.
As explained
earlier the cell
right-
right-click count in the
smallest cross
section should
not be less
than 3x3.

Restore the zoomed view by clicking

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 SIMULATION SETUP
4.3. How to select and change mould and alloy material

Mould material and alloy will be chosen in this step. Choose “Change section” .
Click , to get a better view of the model. Click any of the surrounding box sides, drag
the selection to the far end, right-click. The view should now look like this:

To view all parts in the assembly, click the top 2 boxes. The 2nd box is the mould
material; if this one is selected the view will only show the mould and no parts of the
assembly.

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 SIMULATION SETUP
Right click on the alloy. Choose “Assign material…”. The “Alloy & Mould materials”
window will appear. Click on the material in the “Alloy & Mould materials” window.
Change material and initial temperature and press “Ok”.

Do the same with the rest of the materials.

You do not need to the boxes of every material. This is only done to show which
geometry belongs to which material property.

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 SIMULATION SETUP
4.4. Gating point

A gating point must be set to simulate filling of the casting. Click to view the mould.
Click the xy-plane, drag the selection to the top part of the downsprue, right-click. (The
procedure is shown in the figure below).

Build mesh/box dimensions, “Use part before current section”, “Apply”, “OK”. This
will open up the mold for the gating point.

Choose “Rigging/Gatings” or click . The “Set gating points” window will appear.
Shift+click in the center of the downsprue. The resulting view is shown below. The
gating point has been selected as a section of selected area.

Click “Ok” and press the save-button or choose “File/Save”. This will save all
modifications made in “Initial settings”. Note that all changes (descriptors) will be saved
in the psp-file.

(Saved descriptors can be opened by choosing “Mesh/Build mesh”. The “Parameters of

mesh” window opens. Choose “Load descriptor” in the right bottom corner of the
window. )

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 SIMULATION SETUP
4.5. Flow meters – Measure the efficiency of your gating system

Select a section in the gating channel so that the section of the channel is visible. Click
or choose “Rigging/Flowmeter”. Press shift + left mouse button and click on the
selected section.

You have now created a section that measures the amount of metal that passes through it
in kg/s; litres/s and m/s.

Click on “Ok” to exit the menu.

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 SIMULATION SETUP
4.6. Sensors - Measuring temperature, velocity and pressure

Select a section where you would like to place sensors.

Click on or choose “Rigging/Sensor Elements”. Set measuring sensors in casting
(Blue), and mould (Brown). Press shift + left mouse button and click on the different
areas.

Click on “Ok” to exit the menu.

4.7. Simulation parameters - set filling parameters

Choose “Technology/Filling parameters”. The “Filling parameters” window will appear. Select “Ladle
pouring” in the scroll bar. Change “Pressure height, mm” to 80. Change “Teta” to 0. Change “Stream
diameter” to 40 (double-click in the field and fill in the new value). Click “Ok”.

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 SIMULATION SETUP
4.8. Shrinkage model

Choose “Technology/Shrinkage model”. The “Shrinkage calculation model” window

will appear.

In this window shrinkage can be turned off or modified to correlate with experimental
destructive tests. Set “High Gravity influence”. Click “Ok”.

Note: Gravitation influence has a large impact on shrinkage prediction. Our general
recommendations are:

Type of casting Gravity influence

Steel High
Iron, Grey Low
Iron, Ductile Medium
Non Ferrous High

If casting feeder-less tick off gravity influence.

4.9. Save the casting setup

Press the Save button .

Close the initial settings window.

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 FLOW & SOLID
5. SIMULATION MODULES

Open the “Flow & Solid” module.

By default the model prepared in “Initial settings” will appear in the window. If not, click
the button and choose the .sim or .simdemo file created in step 2.

5.1. Simulation parameters - Set Autostop

Choose “Simulate” and “AutoStop”. The “Auto stop criteria” window will appear. The
endpoint of the simulation is controlled by the auto stop parameters. Here the simulation ends
when the “Volume of liquid phase, %” has reached 0.000. Click “Ok”.

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 FLOW & SOLID
5.2. Simulation parameters - Start simulation

Choose “Simulate” and “Start simulation” or press .

Verification of computational calculations is shown in the bottom right corner. The

simulation is ended when the AutoStop criteria have been met and the time glass button is
inactivated again.

Select viewing “4-view” according to this:

By right clicking in any of the result windows you will be able to Zoom, change field and
leave the 4-view graphical alternative (Zoom to fit window).

Note also that you can view the 3D result in 7 different standard views:

Save the simulation. Close the Flow & Solid window.

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 BROWSER
6. BROWSE THE RESULTS

Post processing of all results from the Flow & Solid simulation can be viewed in the
browser. Open “Browser”. The model appears in the browser window by default. If not,
click and choose your simulation folder.

6.1. Browser navigation

The basics of the browser are to choose output that can be viewed in intervals or at certain
points. The temperature and flow distribution as well as results associated with these can be
viewed from pouring temperature, 100% liquid, to a point set by the “AutoStop” criteria (in
this case to 0% liquid).

The results, such as temperature, liquid phase, shrinkage, velocity etc are viewed by
clicking . A scroll bar appears and the results can be selected.

The results can be played through, paused (stopped) and played frame by frame (i.e.
increment by increment). This control is located on the left side and the increment related
to the viewed result is shown to the right.

As in previous chapters a section in the part can be selected and transparency, 3D view or
2D view can be applied.

Multisection-view
The type of view is controlled by the buttons at the bottom. The desired plane is selected
with the x/y/z buttons. By sliding the next “control”, a cut of the part can be viewed. This
procedure is similar to the previous one but by selecting more than one plane you are able
to use multisection view.

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 BROWSER
6.2. Temperature

Temperature can be viewed as a result of the simulation. Click and choose “Temperature”.
A cross-sectional cut of the part appears. Click and slide the to the right to
view the entire part. Click to play through the increments and view the temperature
distribution. Stop by clicking .

A chosen cut can be selected and viewed by clicking the desired plane, sliding the selection
to the desired cut and confirming by right-clicking or using , . Select
the 2D-view with or use multi-section view.

6.3. Velocity

The velocity result fields are viewed as for temperature. The same controls
are used.

Orientate to this view. The first increment is reached by left-clicking .

Choose the xz-plane and orientate to the desired view

Play through the increments, , and return to the initial increment, .

The scale of the velocity result field is not precise and will be modified to
present a more adequate view of the velocity of the alloy.

Choose “Options” and “Scale value” or tick and enter “1/ 0.50 0.25
/ 0.00” as new values. Click “Apply” and “Ok”.

Play through the increments and note that the scale has changed.

Choose “File/Save Picture” to export an image of the actual view..

Exported images will also contain information about scale, file name and
cut-plane.

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 BROWSER
6.4. Shrinkage

Click and choose “Result field/Shrinkage” and choose “Output transparent” .

The view will show a 3D transparent model with predicted shrinkages. Verify that the last
increment is shown.

Note: Many factors may influence the presence of shrinkage and/or other types of defects

6.5. Video

Choose Result view. Click on the blue arrow to select all records. Click on the “create
video file” icon or choose “File” and “Create video”. Save the video. The video is
finished when the progression bar, bottom right, is completed.

6.6. Autoreport

Choose “File” and “Autoreport” or click on . Set records or choose default. Choose
format for the report and click on “Save” to save the report.

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 CONTACT
7. CONTACT

Novacast Systems AB
Soft Center
SE-372 25 Ronneby
Sweden

Tel: +46 (0)457 46 58 00

Fax: +46 (0)457 156 22
support@novacast.se
www.novacast.se

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 CONTACT
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