Procast Manual PDF

ProCAST
USERS MANUAL & TECHNICAL REFERENCE
Based on
ProCAST
Version 3.1.0
ProCAST Users Manual & Technical Reference. Copyright 1996,

1997 by UES Software, Inc. All rights reserved. Printed in the United
States of America. No part of this manual may be used or reproduced in
any manner whatsoever without written permission. For information
address UES, Software Inc., 4401 Dayton-Xenia Road, Dayton, Ohio
45432-1894, USA. Telephone: 937-426-6900
The following are trademarks or registered trademarks of their

respective companies or organizations.
PATRAN--PDA Engineering
NASTRAN--MacNeal Schwendler Corporation
I-DEAS--Structural Dynamics Research Corporation
PARASOLIDS--Unigraphics Corporation
UES SOFTWARE, INC. TECHNICAL DOCUMENTATION USERS MANUAL & TECHNICAL REFERENCE
TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 1
General Workflow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 6
Graphical Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 8
Manual Organization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 9
Typographic Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 10
Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
Next Step . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 11
STARTING ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 13
DATABASE FACILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 17
TABLE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 23
VIEWING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 - 26
SETTING-UP PROBLEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
General Principles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 1
Fluid Flow Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Mesh and Material Properties . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 2
Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 3
Run Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Radiation Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 5
Micromodeling Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 6
Simulating an Al-7% Si Alloy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 8
Inverse Modeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 - 11
USING PreCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 1
GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 2
CREATE 2-D . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 6
Toolbox . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 8
ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 10
CIRCLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 11
DEL LINE-ARC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 13
DEL REGION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 14
ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 15
LINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 16
MESH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 17
MOVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 19
QUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 20
REGION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 21
RESTORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 22
REVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 23
SPLIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 24
SMOOTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 25
SYMMETRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 26
GRAVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 28
CENTRIFUGAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 32
CHECK GEOM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 36
AXISYM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 41
VIRTUAL MOLD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 42
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 44
DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 46
THERMAL PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 51
FLUID PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 55
FILTER PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 60
ELECTROMAGNETIC PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 61
ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 64
STRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 68
MATERIAL TYPE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70
PROCAST USERS MANUAL PAGE I

PROPERTIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 70
ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 75
MICRO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 77
CAFE MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 82
COUPLED EUTECTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 83
DUCTILE IRON EUTECTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 87
DUCTILE IRON EUTECTOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 89
EQUIAXED DENDRITE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 90
GRAY IRON EUTECTOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 94
GRAY/WHITE IRON EUTECTIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 95
PERITECTIC TRANSFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 97
SCHEIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 102
SOLID TRANSFORMATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 104
INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 110
INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 111
DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 113
CREATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 119
ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 121
MULTI-POINTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 124
INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 128
BOUNDARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 129
DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 131
CURRENT DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 135
DISPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 136
HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 137
INJECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 140
MAGNETIC POTENTIAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 141
MASS SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 142
MOMENTUM SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 143
POINT LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 144
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 145
SURFACE LOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 146
SURFACE NUCLEATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 147
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 148
TURBULENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 149
VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 150
VENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 152
VOLUMETRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 153
ASSIGN SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 154
ADD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 156
ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 156
COPY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157
DELETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157
DESELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157
INTERFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157
LINK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 157
REMAINDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 158
SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 158
SELECT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 159
STORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 159
SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 159
ASSIGN VOLUME . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 161
CURRENT DENSITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162
MASS SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162
MOMENTUM SOURCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162
SURFACE HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162
VOLUMETRIC HEAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 162
PERMEABILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 164
INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 165
PROCAST USERS MANUAL PAGE II

RADIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 166
DATABASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 167
EMISSIVITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 171
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 172
VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 173
ENCLOSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 174
ADD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 175
ASSIGN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 175
DELETE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176
DESELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176
SELECT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176
SELECT ALL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 176
STORE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 177
SOLID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 178
INITIAL CONDITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 180
CONSTANT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 182
EXTRACT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 183
FREE SURFACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 185
RUN PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 186
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 188
GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 189
THERMAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 195
RADIATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 199
FLOW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 202
TURBULENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 210
STRESS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 212
ELECTROMAGNETIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 214
INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 216
CAFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 - 218
USING DataCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 - 1
USING ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 - 1
USING PostCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 1
OPTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 3
X-Y PLOT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 4
GEOMETRY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 16
RADIATION FACE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 17
TEMPERATURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 18
PRESSURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 22
VELOCITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 23
HEAT FLUX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 24
R, G, L . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 25
FEEDING LENGTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 29
ISOCHRONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 31
ALPHA CASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 34
SDAS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 36
ROW SUM ERROR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 38
FACE TO GROUP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 39
FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 40
STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 41
UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 43
MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 - 45
USING ViewCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 1
CONTOUR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 4
VECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 12
STEPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 16
PROCAST USERS MANUAL PAGE III

MATERIALS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 17
PARAMETERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 18
VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 31
PAUSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 - 38
USING INVERSE MODELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1
APPENDIX A
INSTALLING ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A - 5
APPENDIX B
ProCAST FILE USAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
PreCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
DataCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
ProCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
PostCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
ViewCAST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
APPENDIX C
MATHEMATICAL FORMULATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Section 1: Energy Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Section 2: Continuity Equation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Section 3: Momentum Equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-2
Section 4: Turbulent Kinetic Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-3
Section 5: Turbulence Dissipation Rate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Section 6: Eddy Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Section 7: Non-Newtonian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Section 8: Initial and Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 7
Section 9: The View Factor Radiation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 10
Section 10: Finite Element Discretization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 12

Conduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 12
Momentum . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 13
Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 15
Section 11: Time Stepping Algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 16
Section 12: Electromagnetics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 18
Section 13: Stress Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 20
Governing equations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 20
Thermal-Mechanical Contact . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 20
Variational Formulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 21
Finite Element Discretization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 21
Stress Calculation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 22
Radial return mapping algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 25

Section 14: Preconditioned Conjugate Gradient Solver . . . . . . . . . . . . . . . . . . . . . . . . . . C - 26
Section 15: Preconditioned Conjugate Residual Solver . . . . . . . . . . . . . . . . . . . . . . . . . . C - 29
Section 16: Micromodeling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 30
Equiaxed Dendrite Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 30
Coupled Eutectic Growth Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 33
Ductile Iron Eutectic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 36
Gray Iron Eutectoid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 44
Peritectic Transformation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 45
Solid Transformation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 47
Scheil Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 49
Output of Micromodels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 50
PROCAST USERS MANUAL PAGE IV

Equiaxed Dendrite Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 50

Coupled Eutectic Growth Model with Instantaneous Nucleation . . . . . . . . C - 50
Coupled Eutectic Growth Model with Continuous Nucleation . . . . . . . . . . C - 51
Ductile Iron Eutectic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 52
Gray/White Iron Eutectic Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 52
Ductile Iron Eutectoid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 53
Gray Iron Eutectoid Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 53
Peritectic Transformation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 54
Solid Transformation Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 54
Scheil Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 54
Interlamellar spacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 55
Section 17: Cooling Curve Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 57
APPENDIX D
prefixd.dat FILE FORMAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D - 1
APPENDIX E
MATERIAL PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E - 1
APPENDIX F
STRESS MODEL PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F - 1
APPENDIX G
BOUNDARY CONDITION PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . G - 1
APPENDIX H
INTERFACE PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . H - 1
APPENDIX I
RADIATION PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . I - 1
APPENDIX J
MATERIAL MICROMODEL PROPERTY SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . J - 1
APPENDIX K
INVERSE MODELING FILE FORMATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
Inverse settings file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 1
Measurement file . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . K - 3
APPENDIX L
INSTALLING INVERSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . L - 1
INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
PROCAST USERS MANUAL PAGE V

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PROCAST USERS MANUAL PAGE VI

INTRODUCTION
CHAPTER 1
INTRODUCTION
Purpose ProCAST models industrial casting processes and provides tools
which may be applied to the analysis of a wide variety of fully coupled
thermal, fluid, stress, and microstructure prediction problems. This
advanced suite of software modules uses the Finite Element Method
and comprehensive solvers to capture all the physics of the casting
process and lets you see the effects of design decisions . . . on the
computer. Complex geometries including the casting, dies, molds,
risers, gates, and chills can be evaluated as a complete system or they
may be isolated, depending upon your individual project-specific needs.
This Users Guide and Technical Reference is designed to explain how

to use ProCAST, its functions, and options which are available to you.
About ProCAST ProCAST is and has been the technology leader in the casting
simulation market for many years. Key attributes which have
contributed to this leadership position are enhanced in the newest
release of ProCAST. Some of these attributes are discussed here.
Flexibility: ProCAST can provide both process-specific and analysis-

specific simulation support. ProCAST models Sand, Permanent Mold,
Low/High Pressure Die, Investment, Expendable Pattern, and
Continuous casting processes. ProCAST provides fully coupled
thermal-fluid-stress analyses. ProCASTs micromodeling feature
provides the capability to predict the microstructure of castings. Given
the required and appropriate material property data, virtually any cast
material can be accurately modeled.
Graphical User Interface: ProCASTs graphical user interface has been

standardized and structured to guide you through the process for
setting-up, running, and analyzing simulation problems. The database
facility, table maintenance, and viewing tools are examples of the
implementation of this enhanced user interface. The consistent use of
visual clues and objects make it easier to concentrate on the casting
production problem to be solved.
Database Facility: Database capabilities have been integrated into the

components of ProCAST. You access the Database Facility through
push buttons which appear in selected menus of ProCASTs functions
and components. This facility provides a standardized approach for
managing the data associated with your models, whether it is a
material, interface definition, boundary condition, or other property or
attribute. The nature of the information placed in the database depends
upon the material, property, attribute, and/or intended use of the data.
Results: Post-simulation processing is robust. ProCAST provides the
INTRODUCTION, PAGE 1 - 1
INTRODUCTION
capability to extract and view a comprehensive range of contour and

vector plots. For 3D problems, you may view the results from surface
and/or internal perspectives at user defined cross-sections. ProCASTs
visualization tools provide the capability to produce animated views of
the casting process. These animated displays of material flow and the
evolution of strain and temperature in the model, for example, provide
further insight into your process, materials, and finished products. You
may also export simulation results for analysis with other tools.
Benefits: ProCAST provides the tools to help you build a quality

product. The bottom line to any high-tech asset is its ability to
contribute to your business success. The following are just a few
examples of how ProCAST can assist you in achieving these vital
business objectives.
Reduce costs Increase yields
Improve quality Improve quotes
Shorten cycle times Boost sales
Analytical Application ProCAST is a powerful tool to help you engineer your process . . . to
make castings with the required shape and properties, the first time and
every time. When you cast it first on the computer, you avoid the
costly shop floor trial-and-error approach of the past. Some of the
analytical capabilities you may apply to your process include:
Heat flow: ProCAST handles all three primary modes of heat
transfer--conduction, convection and radiation. It also allows
you to account for phase changes (melting, solidification, and
solid-state transformation) and internal heat generation or
dissipation.
Fluid flow: ProCAST offers outstanding fluid flow capabilities for
simulating mold filling. It handles any type of filling, including:
plastics, waxes, powdered metals, and the very high velocities
encountered in high pressure die casting. Turbulent flow,
compressible flow, as well as non-Newtonian flow can be
handled. Vents, trapped gas, low pressure casting, lost foam
processes, the use of filters, and centrifugal processes can all
be accurately simulated.
Stress and Strain: ProCAST calculates thermally induced stresses
simultaneously in all components of the simulation with linear
elastic, elasto-plastic, or elasto-viscoplastic models. Residual
stresses, plastic deformation, hot tears, and final shape of the
casting can all be predicted. ProCAST also automatically
determines gap formation which results from the heat flow
across the interface between the casting and mold in coupled
thermal/stress analyses.
Radiation: The advanced radiation module calculates net radiosity
using the diffuse grey body approximation technique. View
factors, including the shadowing effects, are automatically
calculated. The enclosure can move with respect to the casting
PAGE 1 - 2 PROCAST USERS MANUAL

INTRODUCTION
and the view factors are automatically updated. ProCAST

automatically selects the element faces of the casting which are
participating in the radiation model. This capability greatly
simplifies problem set-up.
Microstructure modeling: Using deterministic modeling, ProCAST
couples the thermal history at any location in a casting with the
nucleation and growth of microstructures. The micromodels
which have been implemented in ProCAST are designed to be
applied to most industrial alloys and are fully coupled with the
macro heat transfer solution.
Inverse modeling: Calculates selected material properties by using
the numerically generated thermal history and measured
temperatures. The inverse solver calculates the optimum
material property which will give the best match between the
measured and calculated cooling curves for the material.
Electromagnetics: ProCAST is capable of fully coupled thermal/fluid
flow/electromagnetic calculations for induction heating and
electromagnetic stirring processes. ProCAST solves the
Maxwell Equations using a magnetic vector potential approach.
High quality tet mesh: ProCAST automatically generates the mesh
for 2D and 3D problems. Geometries which have been
produced in a commercially available CAD and CAE packages
may be used as input for ProCAST. The MeshCAST module
provides the capability to read these geometries, evaluate and
repair these geometries, and generate either a 2D or 3D mesh
for use in ProCAST.
Software features The suite of tools available to you is governed by your software license.
Your professional judgement and individual research, design,
development, or analysis requirements govern which of the available
tools you will use. The ProCAST suite is composed of six software
modules. These six software modules are briefly described below.
PreCAST--performs pre-simulation processing by providing the

capability to define the problem. This includes importing or
creating geometries, defining the materials, interfaces,
boundary conditions, initial conditions, planes of symmetry, and
run parameters. PreCAST also provides the capability to
describe radiation data and apply this data to enclosures and
moving solids.
DataCAST--reads the problem definition data created by PreCAST,

checks the problem definition for errors, converts all units into
CGS units and creates the binary files which will be read by the
simulation module, ProCAST. If errors are encountered, they
will be displayed on the workstation. They will also be written in
a file.
INTRODUCTION
ProCAST--simulates the casting process, performs the finite element

analysis, and generates process results. This data may then be
processed for viewing and analysis.
PostCAST--provides the post-simulation capability to view X-Y plots,

calculate derivative results, and selectively extract data from
the simulation results files and format this data for further
processing, analysis, or viewing.
ViewCAST--provides the capability to view the results of the simulation.

It performs rapid contour plots of all results. For example,
temperature contours can be plotted at every time step
automatically, giving an animated effect. Also, a cutting plane
option allows you to see inside the casting. Menus allow you to
choose views from an extensive list of contours and vectors.
MeshCAST--provides the capability to import geometries from

commercially available CAD and CAE packages, evaluate and
repair the models, and generate a high quality tetrahedral mesh
for use in ProCAST and other FEM analysis software programs.
Technical Features ProCAST offers sophisticated and powerful technology for simulating
your casting and casting process problems. Some of the distinctive
features of this technology are discussed below.
Outstanding fluid flow capabilities for casting simulations are

implemented. The full 3D Navier-Stokes equations are being
solved with no short cuts, along with the coupled energy
equation. A novel implementation of the Volume of Fluid
approach has been used for handling the free surface flow
during and after filling. Natural convection and shrinkage
induced flow are modeled, if desired, throughout the
solidification process.
A unique method for calculating radiation view factors has been

developed for use in ProCAST. It offers radical improvements
in computational efficiency over previously existing techniques.
It is now feasible to recompute view factors which are changing
with time ( as in directionally solidified investment castings ).
Complex geometries may be generated using the multi-point

constraint feature. This feature allows you glue together
pieces of a finite element mesh which do not match. Thus, a
coarse mesh in one region may be joined to a fine mesh in a
second region without a transition. Furthermore, the constraint
weighting factors are generated automatically.
Accurately model the phase transformation of any alloy or pure metal,

INTRODUCTION
to the extent that the fraction solidified function has been

quantified, using the enthalpy formulation employed in
ProCAST. The latent heat evolution cannot be bypassed with a
time step which is too large.
Select an implicit mode for the casting and an explicit mode for the
die with little restriction on time step size using the two-level
time stepping algorithm. The consequence is a substantial
savings in CPU time, particularly if there are many elements in
the die.
The interface heat transfer between the casting and the mold is a
dominant rate controlling mechanism. UES engineers have
developed a very accurate and efficient coincident node
methodology for modeling this phenomenon. Time and/or
temperature dependent coefficients can be accommodated.
Again, automatic selection of faces makes life easier for the
ProCAST user.
Specific technical capabilities of ProCAST include the following:

Efficient solution of transient Navier-Stokes and energy equations
in three dimensions by the finite element method
Volume of Fluid approach for handling the free surface flow in filling
transients
Turbulence modeling using the two equation approach
Trapped gas model accounts for vents and sand permeability
Solves transient, nonlinear heat conduction in three dimensions
Solves the conjugate heat transfer problem with conduction in the
solid along with fluid flow
Non-Newtonian flow, with viscosity as a power law function of shear
rate
Solidification kinetics and solid state transformations, i.e.
micromodeling
Elastic, elastoplastic, and elastoviscoplastic stress analysis,
coupled with thermal-fluid analysis
Eddy current heating, Electromagnetics
Enthalpy formulation for handling phase change
Preconditioned conjugate gradient equation solver
Implicit-explicit, two-level time stepping algorithm with automatic
step-size control
Temperature dependent density, conductivity, specific heat,
viscosity, and emissivity
Coincident and non-coincident node techniques for modeling the
casting-mold interface
Time and/or temperature dependent interface heat transfer
coefficients
Automatic generation of coincident node faces
Time dependent temperature, pressure, and velocity boundary
INTRODUCTION
conditions
Time and/or temperature dependent film coefficients for flux
boundary conditions
Pressure dependent velocity boundary conditions
Diffuse, gray body radiation model
Automatic view factor calculations with moving relative surfaces
Radial and mirror symmetry options available in the radiation model
Hexahedral (brick), tetrahedron, wedge, quadrilateral, and triangular
elements
Multi-point constraints
Automatic calculation of isochrons, temperature gradients,
solidification rates, and cooling rates
Automatic calculation of metallurgical indicators for porosity, grain
size and morphology, etc.
Temperature-time curve plots
Fraction solid-time curve plots
Sophisticated contour and vector plotting program for viewing all
results
Interfaced with PATRAN, IDEAS, IFEM, GFEM, ProEngineer,
ANSYS, ARIES and ANVIL for mesh generation
The path to follow to take advantage of these and other capabilities in

ProCAST, from initial problem definition to analysis of the results, is
straight-forward and typically follows the workflow described below.
Within the framework of this general workflow, ProCAST offers a
variety of tools and methods which may be used to help you refine your
model and generate high quality analyses of your casting process.
This manual will introduce you to the general ProCAST workflow and
provide detailed information about specific commands, functions,
keywords, and operations.
General Workflow The work steps which you follow when using ProCAST depend upon the
nature of your project, your intended use of the results generated by
ProCAST, and the type and quality of model you use as the initial input.
The general workflow, outlined below, illustrates the six general steps
typically followed in a complete ProCAST project.
Step One: Load or create a model

Every ProCAST project begins by obtaining a solid mesh of the
objects to be analyzed. ProCAST allows you to: 1) read solid
meshes which have been created in commercial packages such
as PATRAN, IDEAS, ANVIL, ANSYS, ProEngineer, IFEM, and
GFEM; 2) sketch 2D geometries and generate a 2D solid mesh
with PreCASTs CREATE 2-D functions; or 3) read an IGES
description of a geometrys surface into MeshCAST and
generate a 2-D or 3-D solid mesh.

INTRODUCTION
The solid mesh of the model should contain, as a minimum, the

following information:
Nodal x, y and z coordinates,
Element connectivity, and
Material number assigned to each element.
These options and methods are described in detail in the Using

PreCAST section of this manual.
Step Two: Set-up the problem

PreCAST is used to set-up the problem. Materials, boundary
conditions, interfaces, radiation, and initial conditions are
defined using PreCAST capabilities. Once these components
of the model are defined, they may be assigned to specific
mesh elements or groups of mesh elements.
Step Three: Check the model

DataCAST reads the problem definition data created by
PreCAST, checks the problem definition for errors, converts all
units into CGS units, and creates the binary files which will be
read by the simulation module. If errors are encountered, they
should be corrected before proceeding with the simulation step.
Step Four: Run the simulation

This step actually runs the ProCAST solver. This step involves
most of the cpu-intensive computation and is typically run as a
batch mode background job.
Step Five: Extract the desired results

The results of the simulation done in step four will be contained
in a variety of files and, in most cases, represents a large
volume of data. The unformatted results files are processed in
this step by PostCAST or ViewCAST to extract the specific
information you need for your analysis.
Step Six: View the results

ViewCAST is a collection of tools and displays which allow you
to visualize the results of the simulation. Steps five and six
may be repeated as necessary to provide views of the results
which best meet your specific needs.
Graphical Interface ProCAST uses a graphical interface to facilitate input and interaction
between you and the components of ProCAST. When the PreCAST,
PostCAST, and ViewCAST modules are activated, the work space is
filled with a gray background, the UES logo is placed in the lower right-
hand corner, and a main function banner is displayed. The function
banner is a row of push buttons which appear across the top of the work
space. The number of buttons shown in a function banner and their
INTRODUCTION
capabilities depend upon the specific module which has been activated.
When a module is active, with very few exceptions, this row of buttons
will always be visible.
Function banners allow you to move from one capability to another

within the specific module. You select from the banner by positioning
the cursor over the desired push button and clicking the left mouse
button. Each of the push buttons in the function banner result in an
immediate action and, depending upon the component of ProCAST, will
display either a drop down menu or additional dialog boxes. Each
ProCAST component is discussed in this manual.
ProCAST allows you to set your own preferences for selected aspects
of your workstation environment. These include background and
foreground colors and fonts. These preferences are described in
Appendix M -- User Preferences.
Hot Keys In addition to the graphical interface there are several hot keys which
have been implemented in ProCAST. These keys or key combinations
provide short cuts to commonly performed activities such as zooming
and rotating objects displayed in the work window pane.
The following table summarizes these special keys and the functions
they perform.
Key, Key Combination, Function Performed
or Mouse button
F2 Zoom in by 10%
F3 Zoom out by 10%
X Rotate about the x axis by 10%
Y Rotate about the y axis by 10%
Z Rotate about the z axis by 10%
CTRL+X Rotate about the x axis by -10%
CTRL+Y Rotate about the y axis by -10%
CTRL+Z Rotate about the z axis by -10%
SHIFT+X Rotate about the x axis by 30%
SHIFT+Y Rotate about the y axis by 30%
SHIFT+Z Rotate about the z axis by 30%
CTRL+SHIFT+X Rotate about the x axis by -30%
CTRL+SHIFT+Y Rotate about the x axis by -30%
CTRL+SHIFT+Z Rotate about the x axis by -30%

INTRODUCTION
Key, Key Combination, Function Performed

or Mouse button
SHIFT+LEFT MOUSE Rotates a rotary toggle switch option list back

BUTTON by one selection
DRAG MIDDLE Drag cursor with the middle mouse button

MOUSE BUTTON depressed, zooms on the area in the drag box
CLICK MIDDLE Repositions the plot: the cursor position

MOUSE BUTTON becomes the center of the display
CLICK RIGHT Zooms out while maintaining current orientation

MOUSE BUTTON
Manual Organization This manual is organized to provide a reference for each module in the
ProCAST suite. Accordingly, there is a section dedicated to the
PreCAST, DataCAST, ProCAST, PostCAST, and ViewCAST modules.
The MeshCAST module is documented in two separate manuals,
MeshCAST Users Manual & Technical Reference and MeshCAST
Tutorial & Exercise Manual. These are available under separate cover.
Technical reference materials, such as mathematical formulations and

file formats have been included in this manual as appendices.
In the following pages, each function, keyword and command is

discussed in detail. These discussions include descriptions, syntax
options, and, in many cases, examples. These discussions have been
written in a standard format so that you may quickly find the information
you need.
The following headings are provided for each topic. In the discussion
below, the nature of the information presented in each topic is
described. The following outline briefly describes the information
presented for each topic.
Description: The description states what the function, keyword,

command, or interface button does.
Method: Method presents a description of how to use the command,

feature, or push button. This section discusses all keywords,
commands, place holders, optional values, and mandatory
alternative choices. When it is appropriate, the syntax for
command strings and any required sequence of parameters to
enable the function to properly execute is explained.
If the function is a graphical interface object, such as a button

or menu item, the method section will so state and describe the
alternatives and the results to be expected from its activation.
INTRODUCTION
Remarks: Remarks are used to provide a detailed explanation of the

syntax, each parameter in the syntax, the expected results from
the function or operation, and the impact of specific keyword or
parameter combinations.
The level of detail varies depending upon the specific

command, function or keyword being described. However, at a
minimum, Remarks will explain the intent of each parameter,
the options available for each parameter, and any case
sensitivities.
Remarks are used to provide any special notes, cautions,

warnings or tips about the use of the function which may be
appropriate.
Related Topics: Related Topics is a keyword-oriented cross reference

to information which may be of relevance. Related Topics is an
optional component of the function write-up.
Example: This component may provide one or more illustrations of how

this function works. Example is an optional component of the
function write-up.
Typographic The following typographic and keying conventions are used in this
Conventions manual:
Bold Characters or words which appear in a bold typeface

are elements which you must use literally. These
include: key words, function names, commands,
Italic Characters or words which appear in an italic typeface

represent variable values which you must supply.
[brackets] Items which are enclosed by brackets [ ] are optional.
{braces|bars} Characters and/or words which are enclosed by braces

{ } and separated by a vertical bar indicate a mandatory
choice between two or more items. You must choose
one of the items unless all of the items are also
enclosed in brackets.
ENTER Words and characters in SMALL CAPITAL letters are used

to indicate the name of a keyboard key or key
sequence.
ALT+F1 A plus (+) sign between key names indicates a

combination of keys which you must depress at the
same time. For example, ALT+F1 means to hold down

INTRODUCTION
the ALT KEY while pressing the F1 KEY.
Messages This font (Courier 12cpi) will be used to

indicate messages from the software.
Technical Support Additional technical support is available during normal business hours.
You contact the UES Technical Support Staff by:
Telephone: 410-573-2037
Facsimile: 410-573-2041
E-mail: adi@annapolis.ues.com
Next Step The recommended next step for using ProCAST and this manual is to
read the following topical discussions: Starting ProCAST, Database
Facility, Table Maintenance, and Viewing Tools. These topics are
included in the introduction and provide information about capabilities
and techniques which have been implemented, where applicable, in
ProCAST modules.
INTRODUCTION

STARTING PROCAST
STARTING ProCAST
Description ProCAST is available in either UNIX workstation or Windows NT

versions. The graphical interface and functionality of each of the
ProCAST modules is the same in both versions. However, there are
slight differences in the method for launching a module based upon the
workstation platform.
Specific methods for launching the ProCAST System (PCS) or one of

its modules will be discussed here. A detailed discussion of any
command line parameters for specific modules will be discussed in the
respective section of this manual which describes that module.
Method There are two basic ways to start ProCAST or one of its modules: 1)
typing a command line, or 2) clicking on an icon or menu item. The
systems modular structure allows you to launch individual components,
such as PreCAST, PostCAST, ViewCAST, etc., by name or select them
from a menu on the ProCAST System Interface Screen.
This Interface Screen is shown here. It will be displayed if you type

procast at the NT run or MS-DOS prompt, or type pcs at the Unix
prompt. You may also initiate this screen by clicking on the ProCAST
icon in NT Start Menu.
The options available for initiating any ProCAST session are

summarized in a table in the Remarks section of this write-up.
When a ProCAST module is started, you must supply a file prefix.

ProCAST uses this prefix to uniquely identify the files associated with a
specific project or problem.
STARTING PROCAST
There are two ways to enter this file prefix; 1) you may type the desired
prefix after the module name in the command line at either a Unix or
NT prompt, or 2) you may enter the prefix in a dialog window using the
PCS Interface Screen.
At the top of the Interface Screen are two function buttons. The FILE
button displays a menu which allows you to specify the prefix and the
working directory to be used for this project. This menu is shown here.
When you select PREFIX from the menu, a dialog window is displayed.
Type the prefix name in this window and click on APPLY.
When you select DIRECTORY from the menu, a dialog window is

displayed. Type the directory path and name in this window and click
on APPLY. This dialog window is shown here.
Please note: The DIRECTORY dialog window does not create

directories; they must be created using the appropriate operating
system command prior to running ProCAST.

STARTING PROCAST
After you have provided the prefix name and the directory path, you
may use the EXECUTE button to display a list of the ProCAST
modules. You may select from this list to launch the respective
module. The EXECUTE menu is shown here.
The use of the PCS Interface Screen is an optional method for starting
ProCAST modules. In both Unix and Windows-NT, you may start the
desired module by typing the appropriate information in the prompt
window. Additionally, in Windows-NT you may click on Start, select
Run, and type the appropriate information in the run dialog window.
Remarks The following table summarizes the options for initiating a ProCAST
module session.
Initiating ProCAST Sessions
Windows-NT UNIX
Method Action Method Action

Click on Start, Opens the PCS N/A N/A
Select Run, Screen
Type:
procast {prefix} *
and click OK
Click on the Opens the PCS Click on the Opens the PCS
ProCAST icon on Screen ProCAST icon on Screen
the NT-Start Menu the Desktop. **
or Desktop.
Opens the PCS At the Unix prompt Opens the PCS

at the MS-DOS Screen type: Screen
prompt and press pcs {prefix} *
ENTER. and press ENTER.
At the MS-DOS Starts the At the Unix prompt Starts the

prompt type: respective module. type: respective module.
the module name the module name
{prefix} and press {prefix} *
ENTER. *** and press
ENTER. ***
STARTING PROCAST
Initiating ProCAST Sessions
Windows-NT UNIX
*Entering the prefix in these commands will place the entered value in the prefix dialog
box.
**Assuming that your Unix release supports this option.
***Options and/or parameters for each module are discussed in each
modules section of this manual.
If you type a ProCAST module name (except MeshCAST) at either the

MS-DOS prompt, the NT-Run dialog window, or the Unix prompt and do
not provide a prefix name, you will receive a prompt message to enter
a prefix.
If you are using the NT version, and would like to specify a directory on
another disk, type the following in the directory dialog window:
//x/path/prefix
where: x = the drive name
path = the path name
prefix = this projects name
Some modules have unique command line options. These are

described, as necessary, in the respective chapter in this manual.
Related Topics Using PreCAST, Using DataCAST, Using ProCAST, Using PostCAST,
Using ViewCAST

DATABASE FACILITY
DATABASE FACILITY
Description The Database Facility has been integrated into PreCAST. Access to
the Database Facility is based upon push buttons which appear in
selected menus of PreCAST functions and components. For example,
when you select MATERIALS, INTERFACES, BOUNDARY
CONDITIONS, or RADIATION from the Main Function Banner, a drop
down menu will be displayed. One entry in these menus is
DATABASE. Selecting the DATABASE entry from these menus will
open additional Dialog Boxes, Option Lists, Data Input Windows, or
sub-menus.
ProCASTs Database Facility provides a standardized approach for

managing data. Its graphical interface provides guidance in entering,
maintaining and managing the data associated with your models. The
nature of the information to be placed in the database depends upon
the property, material, attribute, or intended use of the specific data.
The Database Facility is discussed in this section. Specific options for

each use of the DATABASE will be discussed in more detail in their
respective sections of this manual.
Method The figure shown here illustrates the menu which is displayed when the
MATERIALS function in the Main
Function Banner is activated.
To use the Database Facility click the

click on the DATABASE push button.
The Database Facility is context sensitive

and will display data elements from the
database based upon what you are doing
and where you are in PreCAST. Clicking the DATABASE push button
will result in the immediate action to display a table containing any
appropriate data elements which may be in the database.
For illustration purposes we will use the DATABASE function in the

MATERIALS menu. The figure shown here is a table which contains a
list of the materials in the database.
DATABASE FACILITY
Along the top of the table is a group of push buttons which provide
access to specific database functions. The heading for the table, which
appears below these push buttons and above the table entries, will
change depending upon the database elements being displayed.
When you select a function from this group of push buttons, additional
Dialog Boxes, Option Lists, Data Input Windows, or sub-menus will be
displayed. These graphical interface tools will guide you through the
process working with information in the database. The syntax for each
of these data elements and any specific input rules will be explained in
the appropriate section of this manual.
The scroll bar at the left side of the table allows you to move through
table entries, if the number of table entries in the database exceeds
what can be displayed at one time.
Remarks ProCAST provides the capability and flexibility to read, add, copy,
modify, or delete data in its databases.
You cannot delete or modify the base set of material data elements
which come with ProCAST. However, you can copy an entry, rename
it, and modify the newly created entry. You may only delete those data
elements which you have added to the database.
The major capabilities of the Database Facility are described here.

Specific examples of each type of data element and their respectively

DATABASE FACILITY
required options are provided in the appropriate sections of this manual.
READ
Provides the capability to read and/or modify detailed
information about a specific table entry in the database. You
select the desired table entry by clicking on it. The background
of the selected table entry will turn red.
Once a table entry has been selected, click on the READ push
button. This will result in the immediate action to retrieve the
data associated with this table entry and display it in an
appropriate format. From this display you may be able to
select additional levels of detail for viewing. The figure shown
here illustrates the data which is displayed because we selected
the IRON_Pure entry in the MATERIALS DATABASE.
As seen in this example, you may view additional details

associated with IRON_Pure, by clicking any of the check boxes.
Each of these check boxes, in this example, correspond to
material properties. The check boxes are shaded according to
the following criteria: if the box is blue, e.g., Conductivity,
Density, etc., it indicates that some data has been put in the
database for this property. If the box is red it is currently
selected, and if the box is gray, no data has been put in the
DATABASE FACILITY
database for this property.
If this database entry has your USER name, you may change
data or add data elements to this entry. You may store any
data you may have entered by clicking the STORE push button
at the bottom of the display. This will store the data in the
database and close the display.
You may close the display without storing any data you may
have entered by clicking the CANCEL push button at the
bottom of the display.
ADD
Provides the capability to add a data element to the database.
You activate the ADD function by clicking the ADD push button.
This results in the immediate action to display a blank Input
Data Box. In this example adding a material would display an
input box like the one shown here.
It is important to note that, in some cases, some input options

may not be appropriate or may be mutually exclusive. In those
cases, unavailable option check boxes will be red.

DATABASE FACILITY
You may store any data you may have entered in the Input
Data Box by clicking the STORE push button at the bottom of
the box. This will store the data in the database and close the
Input Data Box.
You may close the Input Data Box without storing any data you
may have entered by clicking the CANCEL push button at the
bottom of the box.
COPY
Provides the capability to copy the data associated with one
table entry and rename it. You select the desired table entry by
clicking on it. The background of the selected table entry will
turn red.
Once a table entry has been selected, click on the COPY push
button. This will
result in the
immediate action of
displaying a Text
Input Box , as shown
here. Type the name
of the new entry in the Text Input Box and press the ENTER key.
This will create the new database entry.
DELETE
Provides the capability to delete the data associated with one
table entry. You may only delete an entry from the database if
you are the one who created it, i.e., it has your USER name.
You select the desired table entry by clicking on it. The
background of the selected table entry will turn red.
Once a table entry has been selected, click on the DELETE

push button. This will result
in the immediate action to
display a Confirmation
Window as shown here. To
confirm the deletion, click on
the CONFIRM push button.
This will delete the database
entry. This is not reversible after the confirmation. To cancel
the deletion, click on the CANCEL push button. This will cancel
the deletion and close the confirmation window.
Related Topics TABLE MAINTENANCE, MATERIALS, INTERFACES, BOUNDARY

CONDITIONS, RADIATION, MICRO, STRESS
TABLE MAINTENANCE
TABLE MAINTENANCE
Description Table Maintenance describes ProCASTs standardized approach for

entering data in tables. These table maintenance techniques are used
most heavily in PreCAST. As discussed in the DATABASE FACILITY
section of this manual, database entries are displayed in a tabular form.
You may also use these tabular forms for supplying data for inclusion in
a database. Additionally, ProCAST frequently uses a tabular format for
creating lists other than database entries. Specifying Step Values and
Specifying Temperatures in PostCASTs OPTIONS menu are two
examples where this Table Maintenance approach is used.
Where Table Maintenance is used, the number of columns in a given

table display will vary depending upon the type of data and its intended
use. Specific options for each type of data element will be discussed in
more detail in their respective sections of this manual.
Method The figure shown here illustrates a tabular display of the Conductivity
property for a material. The main parts of the table display are: the
Table Function
Table Function Push Buttons
Push Buttons,
Table Heading(s),
Rotary Toggle
Switches, Table
Entries, and the Table Heading(s)
Edit Value Input
Box.
Rotary Toggle Switches
The number of
columns displayed
and the presence
of rotary toggle Table Entries
switches and their
respective optional
values will depend
upon the exact
nature of the data
to be entered and
the valid attributes
for each specific
data element as
defined by
ProCAST.

TABLE MAINTENANCE
The Table Function Push Buttons may be activated by clicking on the

desired function. These functions accomplish the following activities.
SAVE
This Table Function stores the contents of the table in the
appropriate database. If you have added or changed any table
entries, these will be saved at this time.
GRAPH
This Table Function will graph the data points which are
contained in the table entries. There must be at least two rows
filled out for the function to be graphed. An information
message will be displayed if there are an insufficient number of
data points to plot the graph. If there are no table entries, the
GRAPH push button is ignored. The figure shown here
illustrates the graph of the data in the associated table.
ERASE
This Table Function will delete the entire contents of the table.
This operation is not reversible.
QUIT
This Table Function will result in the immediate action to close
the table display. The data is not stored automatically.
Therefore, any data or changes which you have not stored, will
be discarded.
Rotary Toggle Switches allow you to select a value from the list of valid
entries defined by ProCAST. You select the desired value by clicking
the toggle switch in the table display. This button is a rotary push
button. Each consecutive time you click on the button, the next option
in the list is displayed as the label of the button. The valid choices and
the default value, if any, will be described in the appropriate sections of
this manual. If you change a toggle switch setting, you must use the
TABLE MAINTENANCE
STORE Table Function to retain the change in the database.
Entering data in the table is done by first selecting the desired table
entry. You select a table entry by clicking on it. If the table is empty,
select the area in the
first row under the
first column heading.
This is illustrated in
the figure shown
here.
If the table has data

and you want to add
another data
element, use the
scroll bar, if
necessary, to move
to the end of the
table and select the
first empty area
under the first
column.
Once a table entry is selected the background of that entry will change
to red and the cursor will be placed in the Edit Value Input Box. If the
entry contains data, the data will be displayed in the Edit Value Input
Box. You may then enter or change the data in the Edit Value Input
Box. When you are satisfied with the new data, press ENTER. This will
place the value in the highlighted table entry and move the cursor to the
next available table entry.
Remarks It is important to note that data elements which are entered or changed
in the Table Display are not saved in the database until you use the
STORE Table Function.
Related Topics DATABASE FACILITY, MATERIALS, INTERFACES, BOUNDARY

CONDITIONS, RADIATION, MICRO, STRESS

VIEWING TOOLS
VIEWING TOOLS
Description VIEWING TOOLS have been integrated into ProCAST components as

a standard set of tools which are available and visible any time there is
a geometry displayed in the work window pane. These tools provide
the capability to manipulate the geometry in this window. You may use
these tools to facilitate viewing and working with all or part of the
geometry.
Method The figure shown here illustrates the tools available in the VIEWING
TOOLS toolbox. To use a viewing tool,
click on it when the cursor is over the
desired function. When you select a tool,
ProCAST will perform the designated
function or open an additional input
display. You may use these input
displays to provide additional instructions
or other directions as to how the selected tool is to be used. For
example, when you select the ROTATE function, an input display will
be opened to allow you to input the amount and direction of the rotation.
The method, syntax, and use of the Viewing Tools will be discussed in
this section of the manual. For convenience of presentation, they will
be presented in alphabetical order.
CENTER--Use this push button to reposition a point in the geometry to

the center of the work area. The point you pick will be moved
to the center of the work window pane. Turn this function on by
clicking the left mouse on the CENTER button in the tool box.
The button will turn red when it is active. The figure shown
here illustrates this activity. In the figure on the left, the cursor
is selecting the point to be centered.
After Center
Before Center
The figure on the right shows the geometry as redrawn with the
VIEWING TOOLS
point we selected in the center of the work window pane.
To reposition the geometry, move the cursor to the point in the

window you want moved to the center of the work area and
click the left mouse button. Once the geometry has been
redrawn, the background of the push button will return to gray.
CENTER allows you to reposition the geometry into the center

of the work area. You may choose any part of the window to be
centered.
CENTER determines the point about which rotations take place.

It will redraw the geometry or the portion of the geometry being
displayed at the time you click the left mouse button.
DRAG--Use this push button to reposition the geometry to a specific

point in the work area. Turn this function on by clicking the left
mouse on the DRAG button in the tool box. The button will turn
red when it is active. The figure shown here illustrates this
activity. In figure on the left, the cursor is selecting the point to
which we will drag the center of the geometry.
Before Drag After Drag
The figure on the right shows the geometry as redrawn with the
center of the geometry at the point we selected.
DRAG allows you to reposition the geometry by shifting the

geometry to the point you select with the cursors position. The
green cross will remain in the same position on the model, but
you can move the cross and the model along with it to a new
location. Once the geometry has been redrawn, the
background of the push button will return to gray.
DRAG does not have any effect on the geometry. It will redraw
the geometry or the portion of the geometry being displayed at
the time you click the left mouse button.

VIEWING TOOLS
ELEMENTS---Use this push button to display the Element ID Numbers

for each element of the mesh which is in the work window pane.
You select this function by clicking the ELEMENTS push
button. The element IDs will be drawn in green for each
element currently being displayed. This is illustrated in the
figure shown here. This display capability does not alter the
model or the mesh. It allows you to focus on specific portions
of the model for analysis.
Using the ELEMENTS tool just after using the HIDDEN tool will
limit the elements labeled to the visible surface elements.
ENCLOSURE--Use this toggle switch to turn on any enclosure elements

for viewing along with the casting. Normally, you would only
have enclosure elements for a view factor radiation model.
Turn this function on by clicking the left mouse on the
ENCLOSURE button in the tool box. The button will turn red
when it is active. Successive clicks on the ENCLOSURE
button will toggle the viewing of enclosure elements between
the ON and OFF.
HIDDEN--Use this push button to display a hidden surface view of the

mesh so that only the visible surfaces of the mesh will show.
This is particularly useful for verifying the orientation of the
model. Turn this function on by clicking the left mouse on the
HIDDEN button in the tool box.
VIEWING TOOLS
MAT SELECT--Use this push button to selectively display portions of
the mesh based upon their material ID. When you select this
function by clicking the left mouse button on the MAT SELECT
push button, ProCAST displays a tabular list which contains the
material IDs and the material names in the model. This list is
illustrated in the figure shown here. All of the active materials
will be highlighted with a red background in the list. In this
illustration, the model contains three Material IDs. Only two of
these materials have been selected as active.
You may activate or deactivate a material by clicking on the

desired row in the list. Successive clicks will toggle between
the activated and deactivated.
When you are satisfied with the materials you have selected,
click on the QUIT push button. The Material List display will
close and the work area will be redrawn showing only those
materials you set to be active.
This display capability does not alter the model or the mesh.
These capabilities allow you to focus on specific portions of the
model for analysis.

VIEWING TOOLS
NODES--Use this push button to display the Node ID Numbers for each
node of the mesh which is in the work window pane. You select
this function by clicking the NODES push button. The node
numbers will be drawn in red for each node currently being
displayed. This is illustrated in the figure shown here. This
display capability does not alter the model or the mesh. It
allows you to focus on specific portions of the model for
analysis. Using the NODES tool just after using the HIDDEN
tool will limit the nodes labeled to the visible surface nodes.
RESTORE--Use this push button to restore the geometry to its original

view in the work window pane. Any rotation, node or element
display, zoom or repositioning you may have done while
working with this geometry will be reset.
Activate this push button by clicking the RESTORE button in

the tool box.
ROTATE--Use this push

button to rotate the
image in the work
window pane. When
you click on the
ROTATE push button
an input display will
be shown. This is illustrated in the figure shown here.
Select the degree of rotation about each or every axis by

moving the slider in one or more of the horizontal scroll bars.
You may move the slider by clicking the left mouse button on
either of the directional arrows, by clicking the left mouse
VIEWING TOOLS
button in the slide track, or by clicking and dragging the slider.
You may specify the direction of rotation by clicking the + and

- toggle buttons. These buttons are located to the right of
each scroll bar. The maximum amount of rotation, per axis,
which may be specified at one time is 180 degrees.
The degree of rotation may be set in each of three scroll bars

and in a positive or negative direction. However, the image will
not be rotated until you click on the ROTATE push button.
Selecting the degree of rotation by clicking the directional arrow

at either end of the scroll bars will move the slider one degree
at a time. Selecting the degree of rotation by clicking in the
slide track will jump the slider. Dragging the slider selects the
degree of rotation in a continuous manner proportionate with
the extent of the mouse movement and the speed at which the
mouse moves.
Note that the rotation is about the global triad which appears in
the lower left corner of the display screen. The right-hand rule
is used.
Click on the ROTATE push button in the control box to have

the image moved after you have set the desired degrees of
rotation.
or
Click on RESET to reset all scroll bars to zero and the toggle
buttons to + without moving the image.
or
Click on the QUIT push button in the control box to close the
control box without resetting any values you may have
specified or moving the image.
ZOOM--Use this tool to enlarge or shrink the image in the work window
pane. When you click
on the ZOOM push
button an input
display will be shown.
This is illustrated in
the figure shown here.
Select the amount of enlargement or shrinkage by moving the
slider in the horizontal scroll bar. You may move the slider by
clicking the left mouse button on either of the directional
arrows, by clicking the left mouse button in the slide track, or by
clicking and dragging the slider.
Moving the slider toward the - shrinks the image; toward the

VIEWING TOOLS
+ enlarges the image. The maximum range of magnification

or zoom factor is from .01 of the image to 10 times the size of
the original image. The degree of magnification or shrinkage
may be set in the scroll bar. However, the image will not be
adjusted until you click on the ZOOM push button.
Selecting the degree of magnification by clicking the directional

arrow at either end of the scroll bar will move the slider in small
increments. Selecting the degree of magnification by clicking
in the slide track will jump the slider in larger increments.
Dragging the slider selects the degree of magnification in a
continuous manner.
Click on the ZOOM push button in the control box to have the
image moved after you have set the desired degree of
magnification.
or
Click on RESET to reset the scroll bar to zero without moving
the image.
or
Click on the QUIT push button in the control box to close the
control box without resetting any value you may have specified.
Related Topics HOT KEYS
SETTING-UP PROBLEMS
CHAPTER 2
SETTING-UP PROBLEMS
General Principles When setting up any type of ProCAST analysis, you should keep in
mind the following guidelines:
1. Node and element numbers must be sequential starting from 1.

2. All nodes must be referenced by a least one element.
3. All solid elements must have a material ID. Enclosure elements do
not need a material ID.
4. In general, the denser the mesh, the greater the accuracy of the
results and the longer the cpu time. By judicious selection of
mesh densities, you can often obtain acceptable accuracy with
substantially less simulation time. Concentrate your elements
in areas of high gradients (temperature or pressure), such as at
the casting walls.
5. It is usually better in terms of accuracy to build the mesh for the
mold as well as the casting. It is sometimes possible to mimic
the effect of a mold by applying heat flux boundary conditions
directly on the casting surface. This can save cpu time
because of the reduced number of elements. However, it is
often difficult to predict how the mold will behave, especially if
cooling lines are involved, and therefore determining the
appropriate boundary conditions is not straightforward.
6. Coincident node interfaces can be automatically constructed by
PreCAST where elements with dissimilar material IDs meet.
Each coincident interface is uniquely identified by the material
ID numbers on either side of the interface. If two materials in
your model meet in several different regions which require
varying coincident heat transfer characteristics, you must insure
that unique material ID sets will exist at each interface.
7. Multi-point constraints are also automatically generated by
PreCAST when nodes of one region lie on the faces of
elements in another region. As in the case of the coincident
nodes, the two regions involved are defined by having different
material ID numbers. Therefore, if two pieces of iron ( having
identical material properties ) meet in such a way as to require
a multi-point constraint interface, each piece would be given a
unique material ID number. In PreCAST, both pieces can be
assigned the identical material properties.
8. Multi-point constraints can not be generated across a coincident
node interface.
9. The effect of a complete die cycle can be captured by placing a
heat boundary condition on the coincident node interface
between the casting and the mold. Time functions which toggle
between values of 1 and 0 or vice versa can alternately turn on
the interface heat transfer or the boundary heat transfer.
10. You can use the EXTRACT option in PreCAST to take the
SETTING-UP PROBLEMS, PAGE 2 - 1

SETTING-UP PROBLEMS
temperatures of the mold from the end of one cycle and use
them for the initial temperatures of the next cycle.
11. After running DataCAST, you should always examine the
prefixd.out file. Error or warning messages will be written at the
top of this file. DataCAST will convert any quantity units into
CGS units and the results will also be written in this file. If
something looks out of the ordinary may indicate an error in
data input. The volumes of each material ID are written, in
cm3, in the material data summary .
12. Run the problem in ProCAST for 10 time steps. Use the
post-processing features of ViewCAST to see if, the
temperature initial conditions are correct, the temperature drops
across the coincident interfaces are reasonable, temperature
fields have continuity across the regions where multi-point
constraints exist, heat fluxes have the right magnitude, and
symmetry faces are experiencing zero flux.
Fluid Flow Analysis Setting up a casting problem for a "fluid and thermal" analysis does not
require much additional effort as compared to a "thermal only" analysis.
The analyst needs only to provide a few additional pieces of
information.
Mesh and Material Properties

1. Since no-slip velocity conditions are normally placed everywhere
the metal comes into contact with the mold, each fluid channel
should be at least two elements wide. This would provide only
one "free" node within the channel, providing only a very coarse
estimate of the fluid profile. A channel with at least four
elements across would be more desirable.
2. Wedges, tetrahedrons, and triangles should be used with care in
fluid analyses. All these element types have the potential to be
placed in such a way that all of their nodes lie on the boundary.
When this happens, all the nodal velocities are fixed and the
pressure in the element becomes indeterminate. These are
known as "dead" elements. Many times these elements have a
minimal effect on the analysis. You can usually avoid this
situation by splitting up the meshing volumes such that all the
elements have at least one node which is not on the boundary.
Using brick or quadrilateral elements will usually eliminate this
concern.
3. Any material which will be flowing needs to have the properties of
viscosity, liquidus and solidus temperatures specified, in
addition to the usual thermal properties. Not all the materials in
the ProCAST database have this data, so be careful. Viscosity,
in particular, is often times hard to come by for alloys. Using
the viscosity for the corresponding pure base metal is a good
first approximation.

SETTING-UP PROBLEMS
Boundary Conditions
In general, every boundary of the fluid domain requires either a velocity
or pressure boundary condition, sometimes both. In most situations,
this means that you have to specify the conditions at the inlets and
outlets. The following types of fluid boundary conditions are used in
ProCAST:
1. No-slip conditions specify a zero velocity on a stationary surface.
PreCAST will automatically put a no-slip boundary condition at
all the coincident interface nodes. If the mold walls are not
included in the model, no-slip boundary conditions should be
imposed by specifying a zero u, v, (and w in 3--D) velocities.
No time and/or pressure functions are appropriate for this type
of boundary condition.
2. Specified Velocity conditions are used to set non-zero velocity
vectors on inflow and outflow. For 2D analyses, both the u and
v velocity components must be specified, even if one of them is
zero. Likewise, for a 3D analysis, all three velocities must be
specified. These boundary conditions can be given as
constants or can be functions of time and/or pressure.
3. Specified pressure conditions can be used as inflow or outflow
conditions or on free surfaces. In some cases it may be used to
simply set a reference pressure. Pressure boundary conditions
can be constant or time varying. ProCAST will automatically
set the pressure to zero on the free surfaces in the model. If
the gas model is utilized, then the pressure on each free
surface will be controlled by the gas model. All models,
whether they are free surface or not, should have at least one
specified pressure somewhere in the fluid region. If no
specified pressures are given in a free surface model, the
calculation will be fine until the free surface is forced out of the
model. Once filled, a specified pressure condition is needed.
4. Symmetry conditions force the velocities to align with the
symmetry planes such that the normal components are zero.
5. Periodic conditions link two periodic surfaces together. Pressures
along the periodic surfaces are equated. The velocities are
linked via the appropriate transformation.
It is important to note that the "natural" boundary condition for

the pressure equation is a zero gradient normal to the wall.
This situation promotes a velocity field which runs parallel to
the wall, which is usually desirable. Therefore, in situations
when the flow does not run parallel to a wall, either a velocity or
a pressure boundary condition is required.
Example 1

SETTING-UP PROBLEMS
First, consider an axisymmetric geometry as shown below.
The filling transient is not

considered in this analysis. metal
Instead, the subsequent

circulation flows are of interest.
This analysis can be run one of
two ways: 1) the free surface C
L mold
model can be used which will
include the effects of the liquid
level dropping in the risers, or 2)
these effects can be ignored and
the free surface model will not be
actuated.
The following fluid boundary conditions are required whether or not the
free surface model is used:
1. u = 0 along the center line (a symmetry condition could be used
just as well).
2. P = 0 along the tops of the risers (if the free surface touches the
top row of nodes, this boundary condition will be needed).
3. u = v = 0 along the coincident interface. This boundary condition
will automatically be included by PreCAST.
The free surface model will work best if there is at least one empty row
of elements at the top of the risers. The initial free surface level can be
adjusted using the LVSURF parameter in the prefixp.dat file or in the
RUN PARAMETERS function of PreCAST.
Example 2
A simple filling analysis is considered next. In this analysis, the mold is
not included.
Top of riser
The boundary conditions for this model

are as follows:
1. u = u_inlet, v = 0 at the filling gate
2. P = 0 along the top of the riser
3. u = v = 0, everywhere else
mold
It is important to specify no-slip velocities
Filling gate
last when working in PreCAST. Specified
velocities are imposed in sequential
order. In that way, no-slip velocities will gas
overwrite inlet velocities at the edges of

the inlet region, as they should.
metal
Example 3
In the next model, a pressurized gas

SETTING-UP PROBLEMS
region is used to drive the metal into the upper mold region.
The analysis is started with the lower melt area already filled. The
boundary conditions for this analysis are:
1. Symmetry condition specified along the left edge of the model.
2. The pressure boundary condition will be governed by the gas
model. If an injection is specified into the gas region above the
melt, then the pressure will be mechanistically computed for
that expanding region. The pressure on the metal surface
being forced up the sprue will be determined by considering
vents and/or gas porosity within the mold.
3. No-slip boundary conditions will be imposed for the interface by
PreCAST. More no-slip boundary conditions are required down
in the melt area.
Run Parameters
Some of the parameters in the prefixp.dat file need special attention for
a flow analysis.
1. FLOW = 1, turns the flow model on
2. COURANT = 10. to 50. Higher courant limits will allow the use of
larger time steps. However, if excessive restarts are the result,
the courant number should be reduced.
3. LVSURF = 0.98 will switch from the filling model to a circulatory
flow model when the metal region is 98% full. If the switch is
undesirable, then set LVSURF > 1.0.
4. CONVV = 0.05, sets the velocity convergence to 5 percent. This
will require the velocity predictions of the momentum equations
to stabilize to within 5 percent at each time step. Adjusting this
parameter up or down may have a large effect on the allowable
time step.
Radiation Problems The effects of radiation can be handled either by the "simple" method,
where you specify an emissivity and an ambient temperature in a heat
flux boundary condition, or the more sophisticated view factor method.
The comments below are directed towards this latter class of problems.
1. A heat flux boundary condition, containing an emissivity and with
view factors turned on, should be applied to all external
surfaces of the casting, with the exception of symmetry faces.
2. The view factor radiation model requires a totally enclosed system.
Any gaps in the enclosure behave like "black holes" through
which energy escapes, yielding unpredictable results. When
analyzing a casting with planar or axial symmetry, make sure
that the correct angles are being subtended, such that if the
symmetric portion of the enclosure was rotated around, the
casting would be totally surrounded. Also, if the enclosure is
moving relative to the casting or vice versa, make sure that the
casting will not penetrate through the walls during the course of
the analysis.

SETTING-UP PROBLEMS
3. The walls which comprise the enclosure in a 3D radiation analysis

may be modeled with 2D elements, i.e., triangles and
quadrilaterals, or by solid elements. Similarly, in a 2D radiation
analysis, the enclosure may be built with either 1D bar
elements or 2D solid elements.
4. If 2D elements are used to build the enclosure in a 3D problem,
make sure that the normal vectors of these elements are facing
inward. Also, at a minimum, you need to assign temperatures
and emissivities to these types of elements (and to 1D
elements in a 2D problem).
5. If 3D elements are used to build the enclosure, a heat flux
boundary condition, containing an emissivity and with view
factors turned on, should be applied to all the inwardly directed
faces. Take care not to apply this type of boundary condition,
with view factors on, to the outside of a solid element
enclosure.
6. Place your global coordinate system near the geometric center of
your casting. This will ensure maximum numerical accuracy in
the view factor calculations.
7. Setting RDEBUG to 6 under the RUN PARAMETERS will cause
ProCAST to produce the prefix.view and prefix.serr files after
the first time step. These can be quite useful in debugging
problems with the geometry or radiation boundary conditions.
These files contain, respectively, face to group view factors and
row sum errors. Contour plots of these quantities can be
produced by ViewCAST.
8. If you are modeling one component of a symmetric structure, you
can use ViewCAST to replicate the symmetric parts. Then you
can verify that there are no overlapping regions or gaps present
in your model.
9. Use PostCAST to output a radiation face neutral file, prefixr.ntl.
Use PATRAN or IDEAS to look at this model to verify that there
are no holes in the radiation model.
10. After enough time steps have been computed, check that the
enclosure is moving at the right speed. You can see this with
ViewCAST.
Micromodeling Analysis The ultimate aim of micromodeling is to predict the microstructure of

castings. The mechanical properties of the castings can then be
predicted from a knowledge of the microstructure. Micromodels can not
accomplish this task alone however. They have to be incorporated into
macromodels to achieve this goal. The coupling of the macro- and
micromodels can be accomplished through the source term in the
energy equation. The rate of evolution of the fraction of solid is
calculated by the micromodels, which controls the release of latent
heat.

SETTING-UP PROBLEMS
Liquid
Delta Liquid + Delta
Peritectic Reaction
Delta P
+
Gamma Liquid + Gamma
G Liquid + Graphite
Gamma
A E
Eutectic Reaction
Gamma + Graphite
Gamma
+ Eutectoid Reaction
Ferrite
D
Ferrite Ferrite + Graphite
Fe X
wt % C
Figure 2-1 Binary Stable Fe - C Phase Diagram
Figure 2-1 illustrates a stable binary Fe-C phase diagram, showing

three types of major reactions:
1. Peritectic Reaction (P) : L +
2. Eutectic Reaction (E) : L + Gr
3. Eutectoid Reaction (D) : + Gr
Where L symbolizes liquid, and stand for two different
types of body centered cubic (b.c.c.) ferrite, stands for the
face centered cubic (f.c.c.) austenite phase, and Gr stands for
graphite.
Take, for example, a gray iron alloy of carbon equivalent X.

Solidification will begin at point G on the phase diagram by forming
austenite dendrites. Austenite dendrites will continue to form until the
eutectic temperature, given by the line AE, is reached. At this time, all
the remaining liquid undergoes a transformation by which the liquid
solidifies as austenite and graphite. As the temperature continues to
drop, the solute concentration ( i.e., the carbon concentration )
decreases following the AD line. When the eutectoid temperature
corresponding to the point D is reached, the austenite phase transforms
into ferrite and graphite.
Micromodels are activated in ProCAST by choosing a suitable value for

the MICRO parameter in the prefixp.dat file. The following table lists
values for the MICRO parameter corresponding to the different
micromodels:

SETTING-UP PROBLEMS
MODEL MICRO
Eutectic Ductile Iron 1
Equiaxed Dendrite 2
Coupled Eutectic with Instantaneous Nucleation 4
Coupled Eutectic with Continuous Nucleation 8
Eutectic Gray/White Iron 16
Eutectoid Ductile Iron 32
Gray Iron Eutectoid 64
Peritectic Transformation 128
Solid State Transformations 256
Scheil Model 512
A combination of different micromodels can be chosen in a single run

by adding the appropriate MICRO parameters corresponding to
individual micromodels. When you run a PreCAST session and assign
the desired micromodels to the particular material, the MICRO
parameter is automatically assigned the right value. In our example,
the equiaxed dendrite solidification beginning at point G is activated by
setting MICRO to 2. The eutectic transformation at AE is turned on by
adding 4 to MICRO, which activates the Coupled Eutectic Model with
Instantaneous Nucleation. The MICRO parameter will be automatically
be assigned a value of 6.
The MFREQ parameter in the prefixp.dat file governs the frequency at

which the relevant microstructural results are stored for restart purposes
and for post-processing.
Giving the LINSRC parameter a value of 1 in the prefixp.dat file

switches on linearization of the source term. In this option, a part of the
source term is added to the system matrix, thereby enhancing stability.
Simulating an Al-7% Si There is more to running micromodeling analyses than setting the
Alloy parameters described above. Some material data about the alloy also
has to be supplied. Suppose that you want to simulate the solidification
of an Al-7%Si alloy in a sand mold. Consider the binary phase
diagram, shown in Figure 2-2, for the Al-Si system. For this alloy,
equiaxed solidification begins when the liquidus temperature, 618(C, is
reached. Equiaxed dendrites continue to grow until the eutectic
temperature, 577(C, is reached and eutectic solidification begins.

SETTING-UP PROBLEMS
1414
660.5
618
577
Al
Si
1.6 7 12.6
Al wt % Si Si
Figure 2-2 Binary Al - Si Phase Diagram
Note the following aspects of the above phase diagram:

1. Melting point of pure Al = 660.5(C
2. Melting point of pure Si = 1414(C
3. Alloy composition = 7%
4. Eutectic temperature = 577(C
5. Primary transformation temperature = 618(C
6. Liquidus slope, taken as constant = (577--660.5)/12.6 = -
6.63(C/wt%
7. Solute partition coefficient, taken as constant = 1.6 / 12.6 = 0.13
(evaluated at eutectic temperature).
We will model this alloy with a combination of equiaxed dendrite and

coupled eutectic solidification with instantaneous nucleation.
1. In the MATERIALS menu, select MICRO and then press the ADD
button. Select EQUIAXED DENDRITE..
2. Give the GIBBS---THOMPSON COEFF a value of 2.0e-7 mK. (
Kurz and Fisher, Fundamentals of Solidification )
3. ALLOY COMPOSITION = 7.0
4. TRANSF. TEMP = 618(C (assuming that it does not vary with
cooling rate)
5. PARTITION COEFF. = 0.13
6. DIFFUSIVITY = 3.0e-9 m 2/s
7. LIQUIDUS SLOPE = -6.63(C/wt%
8. SUBSTRATE DENSITY: Suppose you obtained from experiment
that the grain size in the castings varies from 0.032 cm to 0.052
cm when the corresponding cooling rates vary from 0.2 (C/s to
10 (C/s. Using the equation,

SETTING-UP PROBLEMS
4
% RL # N
1
3
(3.4.1)
3
where RL is the grain size and N is the substrate

density, the following table may be constructed:
Cooling Rate ((C/s) Substrate Density (cm-3)
0.2 1697.86
10 7285.53
9. Click on STORE.
10. In the MATERIALS menu, again select MICRO, then ADD. Select
COUPLED EUTECTIC, then INSTANTANEOUS
NUCLEATION. We make an assumption of stable eutectic
growth.
11. STABLE GROWTH CONSTANT = 1.0e-5 cm/sec/K2
12. METASTABLE GROWTH CONSTANT = 4.0e-5 cm/sec/K2
13. SOLVENT MELTING POINT = 660.5 (C
14. CRITICAL COOLING RATE = 300 (C/s
15. EUTECTIC COMPOSITION = 12.6
16. TRANSF. TEMP = 577 (C
17. PARTITION COEFF. = 0.13
18. Let us assume that you obtained the following data from
experiment:
Cooling Rate ((C/s) Substrate Density (cm-3)
0.5 1.0e5
12.2 4.0e5
Here substrate density refers to eutectic cell density, which can

be measured by simple metallographic analysis of the
microstructure.

SETTING-UP PROBLEMS
19. The LAMELLAR SPACING table is arbitrary in this case because

we already chose to avoid a metastable eutectic structure by
intentionally inputting a high value of the CRITICAL COOLING
RATE, i.e., 300 (C/s. However, for the sake of completion, you
may enter following data: Note that with an increase in the
cooling rate, the lamellar spacing decreases.
Cooling Rate ((C/s) Lamellar Spacing ()m)

0.3 10
15 2
20. Click on STORE.

21. Select MATERIALS, MICRO, and ASSIGN. The two models that
you just put in should appear in the database list. You can
assign both of them to the same material ID.
Inverse Modeling Inverse modeling allows you to use the thermal history generated by
ProCAST as an input for deriving thermophysical properties, initial
conditions, or boundary conditions. In order to perform the selected
inverse calculations all other aspects of a problem must be set-up. This
means that information about the following components of the problem
must be defined.
geometry,
material properties,
interface heat transfers,
boundary conditions,
initial conditions, and
run parameters.
You may use menu options in the MATERIALS, INTERFACE,

BOUNDARY CONDITIONS, and RUN PARAMETERS menus to
specify the component and properties to be calculated using the inverse
methodology.
To use the inverse method you should keep the following things in
mind:
1. The inverse calculation may be performed for only one material at
a time. If the material to be studied is used in more than one
domain, all corresponding domains will automatically be
selected.
2. The inverse calculation for the Interface may be performed in
conjunction with the inverse calculation for the Boundary
Condition. It may not be performed in conjunction with the
inverse calculation for the material properties.

SETTING-UP PROBLEMS
3. The inverse calculation for the Boundary Condition may be

performed in conjunction with the inverse calculation for the
Interface. It may not be performed in conjunction with the
inverse calculation for the material properties.
4. The inverse calculation may be performed, at the same time, for all
film coefficient (H), flux (Q), and emissivity (E) values for one
or more Heat boundary conditions.
5. In a thermophysical calculation, it is possible to determine, at the
same time, specific heat, thermal conductivity, and latent heat
properties. However, you must be careful that these properties
are not totally independent. The diffusivity is the ratio of the
thermal conductivity over the specific heat and the specific heat
and the latent heat are both contained in the enthalpy.
6. The inverse calculation will converge much faster if the initial beta
values (i.e., initial guesses) are closest to the final values.
Therefore, you are advised to run the direct calculation with
ProCAST using the initial guess before running the inverse
calculation. You should check that the calculated curves
generated from the results of the direct calculation are not too
far from the measured curves.
7. If a property is defined as both temperature and time dependant, it
is strongly advised not to perform an inverse calculation in the
same time on both the temperature-dependant beta values and
the time-dependant beta values. In this case, it is advisable to
perform the inverse calculation with one set of beta values
while keeping the others constant and then repeat the
calculation vice-versa.

USING PRECAST
CHAPTER 3
USING PreCAST
Description PreCAST provides the pre-simulation capability to define the problem.

Setting-up the problem is the task of identifying every component of the
problem, defining all of the properties which are relevant to the
components of the problem, and associating properties, attributes, and
conditions to each component.
Method PreCAST runs in a either a Unix or a Microsoft Windows NT session

window.
PreCAST can be started using the following command line instruction at

the session window prompt or the Run Dialog Window:
precast {prefix} ENTER
Prefix is a required parameter and you should enter the name you want
given to this project.
PreCAST may also be started from the EXECUTE menu in the PCS
screen.
Remarks If you start a PreCAST session without the prefix parameter shown
above, you will be prompted to enter a prefix.
Prior to starting PreCAST, you should change the active directory to the
one which contains your project.
When PreCAST is activated, it will display a work space with a gray

background, the UES logo in the lower right-hand corner, and a Main
Function Banner across the top of the work space. You may use the
push buttons in this banner to navigate through the functions of
PreCAST.
These functions are:

GEOMETRY, MATERIALS, INTERFACE, BOUNDARY,
RADIATION, INITIAL CONDITIONS, RUN PARAMETERS, and
EXIT
Each of these functions are described in the following pages. They are
presented in the order shown above which corresponds to their left-to-
right placement in the Function Banner. This also approximates the
order in which you would ordinarily use the functions of PreCAST.
Related Topics GEOMETRY, MATERIALS, INTERFACE, BOUNDARY CONDITIONS,

RADIATION, INITIAL CONDITIONS, RUN PARAMETERS, EXIT
GEOMETRY
USING PRECAST, PAGE 3 - 1

GEOMETRY
Description GEOMETRY is a push button in the Main Function Banner. The

GEOMETRY functions of PreCAST enable you to load or create the
geometry of the part(s) or process to be modeled. These functions are
also used to specify attributes of the model. Activating the
GEOMETRY push button opens a menu of these geometry and model
attribute functions. Selections from the menu provide capabilities which
will be discussed in this section.
Method GEOMETRY is activated by clicking on it. The initial menu is shown

here. Please note that the shaded options on this initial menu are not
available until after you have specified
the UNITS or loaded a RESTART or
MESHCAST file. You select other
functions from this menu by clicking the
desired function.
The units button on this menu displays

an option list from which you may select
the units of length which will apply to all
dimensions in the model. After
specifying the UNITS you may select the
appropriate Input File Option.
Once you have specified the units of

length or loaded a RESTART or
NEUTRAL file, the initial shading of all
menu options will change to gray. You
may then select other functions to be
performed.
In most cases, when you select a

function from this menu PreCAST will
display additional Dialog Boxes, Option
Lists, Data Input Windows, or sub-
menus. These graphical interface tools
will guide you through the process of specifying information about your
model and the type of analysis to be performed.
The AXISYM and VIRTUAL MOLD functions on this menu are toggle
switches. In the off position the buttons are gray. In the on position
these buttons are highlighted in burgundy.

GEOMETRY
Remarks Specifying the units of length: You select the

desired units by clicking the UNITS push
button in the menu. Clicking this button opens
an Option List. Choose the desired units of
length by clicking on the corresponding toggle
button in the option list. When you select a
unit of length, the corresponding toggle button
will change color and appearance and the
Option List will be closed. The choices available in this list are mutually
exclusive. Selecting a second unit of length will deselect the prior
selection. The units selected will be applied to all nodal coordinates
read from the input file and to any points defining symmetry planes or
an axis of rotation. The selection of units does not change the source
data file.
For RESTART and MESHCAST files, the units of length will be defined
in the input file data.
Selecting the input source:

PreCAST supports a broad range
of input file formats. You select
the input file type by clicking on the
type of file you want. When you select the type of file to be loaded
from the menu, you will be prompted for the file name. PreCAST will
display the file prefix you entered when you started the current session
of PreCAST. It will also display the appropriate suffix for the file type
you have chosen. You may accept this information or you may type a
different file name in the Data Input Window as shown here.
When you are satisfied that the file name you want to load is entered in
the Data Input Window, click on the APPLY push button to load the file
or press ENTER.
You may read more than one input file during a single PreCAST
session by re-selecting an input file format and completing the
Selecting the input source sequence of actions described above.
You may click on the CANCEL button at any time. This will cancel the
Data Input Window without loading a file.

GEOMETRY
The input file types and the data types which are supported by
PreCAST are described below:
RESTART--typically resumes a previous PreCAST job. This option
reads a previously generated prefixd.dat file. If you use the
same prefix, the old prefixd.dat file will be overwritten. File
suffix: d.dat
MESHCAST--reads a ProCAST/MeshCAST neutral file. The format for
this file is the same as the prefixd.dat file format. File suffix:
d.dat
PATRAN--reads a PATRAN neutral file. The following data types are
handled:
1- Node coordinates
2- Element connectivity and material ID
8- Nodal displacements (used to indicate pressure/velocity
locations)
10 - Nodal temperatures
16 - Heat fluxes on element faces
File suffix: .out
IDEAS--reads an IDEAS universal file, Levels 4, 5, 6, and Master
Series. The following data types are handled:
151 - Header
15 - Nodal coordinates, single precision
781, 2411 - Nodal coordinates, double precision
71, 780, 2412 - Element connectivity and material ID
164 - Units
755 - Nodal temperatures
756 - Heat flux on element faces
780 - Element connectivity and material ID
781 - Nodal coordinates, double precision
782 - Heat flux on element faces
File suffix: .unv
ANVIL--reads an ANVIL universal file. The following data types are
handled:
NODE - Nodal coordinates
TRIA1 - Linear triangles
QUAD1 - Linear quadrilaterals
TETR1 - Linear tetrahedrons
PENT1 - Linear wedges
HEXA1 - Linear bricks
File suffix: .out
ANSYS--looks for prefix.ans file and reads ANSYS files 14 and 15.
PreCAST expects to find two files named prefix.14 and
prefix.15. These contain element connectivity data and nodal
coordinates, respectively. File suffix: .ans or .14 and .15
ARIES--reads element and node information from and ARIES geometry
file. File suffix: .out

GEOMETRY
When you click on the APPLY push button in the dialog box, PreCAST
loads the input file and displays information about the status of that file
in a message box. The following example shows a message box as a
result of loading a RESTART file.
The message box provides information about: the number of elements,

the number of nodes, the number of materials, a summary of the
boundary conditions, and if the model contains an enclosure.
When you have read the message box, click on the QUIT push button
to close this message box.
Related Topics Each menu item shown above is discussed in the following pages.

GEOMETRY
GEOMETRY
CREATE 2-D
Description CREATE 2-D is a push button in the GEOMETRY menu. PreCAST

provides the capability to create a geometry and mesh of the part(s) or
process to be modeled. Clicking on CREATE 2-D opens a simple CAD-
type interface. This CAD tool will allow you to draw a geometry and
generate a mesh for that geometry. This 2-D geometry and mesh may
then be used for further analysis.
Method CREATE 2-D is activated by clicking on it. Selecting CREATE 2-D

results in the immediate action to open a dialog box requesting you to
specify the minimum and maximum X and Y coordinates for the
drawing area.
These values are
used for scaling the
input in the drawing
area.
To enter the values,

place the cursor in
the appropriate input box and type the desired value. You may move
from one input box to another using the cursor or by pressing the TAB
key.
When you are satisfied with the values you have entered, click on the
APPLY push button. This will apply the constraints to the drawing area
and open the CAD tool.
You may click on the CANCEL button at any time. This will cancel the
dialog box and return to the GEOMETRY menu.
Remarks The CAD capability provided in PreCAST consists of a drawing area

and a toolbox. It allows you to create a geometry consisting of straight
lines, arcs, and circles and generate a mesh for this geometry. The
toolbox and its tools are described in the sections of this manual which
are labeled: CREATE 2-D--Toolbox--Tool. Where Tool will be
the name of the individual tool such as, LINE, ARC, RESTORE, etc.

GEOMETRY
The general procedure for generating 2-D mesh for analysis consists of
the following major steps:
(1) Create the line drawing. Using the drawing tools in the toolbox to
create the geometry. Each of these tools is discussed in the
following sections.
(2) Select the lines which border each region of the model. Unique
region identifiers are assigned automatically.
(3) Generate the mesh. In each region of the geometry, you may
specify a targeted length for the mesh elements. The mesh
density must be uniform within a region of the model. You may
choose either a triangular or quadrilateral mesh for the entire
model.
(4) Smooth the mesh. Enhance the mesh by using the smooth tool
until the mesh appears to be smooth.
(5) Quit CREATE 2-D. Press the QUIT push button in the toolbox to
exit the 2-D CAD tool. Clicking QUIT before a mesh is
generated will result in creating the prefix.geom file.
The mesh of triangular or quadrilateral elements of fairly uniform size is

created within seconds. This allows you to obtain an overall
representation of the model and/or set up problems for parametric
studies very quickly.
Related Topics CREATE 2-D--Toolbox and its associated tools.

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox
Description The CREATE 2-D Toolbox is part of the 2-D drawing area which is
opened as a result of clicking the APPLY push button after specifying
the minimum and maximum X and Y coordinates for the drawing area
in the CREATE 2-D dialog box.
Some of the tools in the toolbox are push buttons which result in an
immediate action such as RESTORE or SMOOTH. Other tools are
toggle switches which enable or disable specific capabilities such as
LINE and ARC. Still other tools are push buttons which open a dialog
box to guide you in providing the specific information required to
complete the selected function. An example of this last group is the
MESH push button.
Method Toolbox is displayed and available because you activated the CREATE
2-D push button in the GEOMETRY menu. The drawing area and the
toolbox are shown here.
You may activate a specific tool by clicking on the desired tool.
To enter values in the coordinate input boxes, place the cursor in the
appropriate input box and type the desired value. You may move from
one input box to the other using the cursor or by pressing the TAB key.
The use of these boxes is explained in the discussion of the appropriate
tools.

GEOMETRY
If you use the coordinate input boxes, press the ENTER key when you
are satisfied with the values you have entered. This will cause the
immediate execution of the function you have chosen.
Remarks You may click on the QUIT button at any time. This will cancel the
CREATE 2-D screen and exit the 2-D CAD tool. Clicking QUIT before
a mesh is generated will result in creating the prefix.geom file.
Related Topics CREATE 2-D--Toolbox--Tools

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--ARC
Description The ARC tool allows you to create a single arc between two points. It is
a toggle switch in the CREATE 2-D Toolbox.
Method Select the ARC tool by clicking the ARC push button in the Toolbox.
You may specify the two points by moving the cursor to the desired
locations in the drawing area and clicking the left mouse button or you
may type the X and Y coordinates in the coordinate input boxes. You
may also use a combination of these two methods to specify the ends
of the arc to be drawn.
Press the ENTER key when you are satisfied with the values you have
entered. This will display the specified point in the drawing area.
Repeat the input steps to provide the second point of the arc to be
drawn.
A RADIUS dialog box will be displayed when you have specified the
two ends of the arc. You must supply the
radius of the arc to be drawn and it must be
greater than half the distance between the
two points. Type the radius in the dialog
box and press the ENTER key when you are
satisfied with the value you have entered.
The arc will be drawn in the drawing area.
Remarks You may start or end an arc on an existing point in the drawing area by
moving the cursor close to that point and clicking the middle mouse
button.
After the arc has been drawn you may reverse its orientation by clicking
the REVERSE push button in the toolbox.
The ARC function remains active until you select another tool from the
toolbox.
You may delete an arc by using the DEL LINE-ARC tool.
Related Topics DEL LINE-ARC, REVERSE

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--CIRCLE
Description The CIRCLE tool enables you to create a full circle consisting of four
arcs. CIRCLE is a push button in the CREATE 2-D toolbox. It opens
an option list which allows you to choose one of two methods for
creating the circle.
Method Activate the CIRCLE function by

clicking the CIRCLE push button. An
option list will be displayed to give you a
choice of techniques for defining where
and how the circle will be drawn.
These options are:

CENTER-RADIUS--you specify the center point coordinates and the
radius of the circle to be drawn.
TWO POINTS--you specify two diametrically opposed points in the
geometry.
In either technique, you may specify the points by moving the cursor to
the desired location in the drawing area and clicking the left mouse
button or you may type the X and Y coordinates in the coordinate input
boxes. You may also use a combination of these two methods.
entered. This will display the specified point in the drawing area.
Repeat the input steps, as needed, to provide all required information.
If you choose the CENTER-RADIUS

option, a radius dialog box will be
displayed. You must supply the radius
of the circle to be drawn.
Type the radius in the dialog box and

press the ENTER key when you are
satisfied with the value you have entered. The circle will be drawn in
the drawing area.

GEOMETRY
Remarks You may attach a circle to an existing point in the drawing area by
button.
The CIRCLE function and the option chosen will remain active until you
select another tool from the toolbox.
You may delete an arc or arcs by using the DEL LINE-ARC tool.
Related Topics ARC, DEL-LINE-ARC

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--DEL LINE-ARC
Description The DEL LINE-ARC tool allows you to delete an existing line or arc.
DEL LINE-ARC is a push button in the CREATE 2-D Toolbox.
Method Select the DEL LINE-ARC tool by clicking the DEL LINE-ARC push
button in the Toolbox.
Move the cursor to the desired line or arc and click the left mouse
button to highlight the item to be deleted.
You may also select the item to be
deleted by sweeping the cursor across
the line or arc while holding the mouse
button. A confirmation window will ask
you to confirm the deletion. Click on the
YES push button in the confirmation
window to delete the line or arc.
Clicking on the YES push button results in the immediate action to

delete the line or arc. Clicking on the NO push button cancels the
delete request.
Remarks Lines or arcs are deleted one at a time. You may select another line or
arc for deletion by moving the cursor to that specific line or arc and
clicking the left mouse button. The deletion of lines or arcs is not
reversible after you confirm the deletion.
The DEL LINE-ARC function remains active until you select another
tool from the toolbox.
Related Topics ARC, LINE

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--DEL REGION
Description The DEL REGION tool allows you to delete the definition of a region in
the model. DEL REGION is a push button in the CREATE 2-D Toolbox
which opens a table listing all region definitions in the model.
Method Select the region definition to be deleted by clicking on the desired

definition.
Selecting a region in the table will

highlight the entry with a red background.
At the same time, the outline of the region
will change from cyan to yellow in the
drawing area.
Once the desired region is selected, click

on the DELETE push button in the table to
complete the deletion process.
You may exit the DEL REGION tool by

clicking the QUIT push button in the table.
Remarks Region definitions are deleted one at a

time. You may select another region
definition for deletion by moving the
cursor to that specific line in the table, clicking the left mouse button,
and then clicking the DELETE push button. The DEL REGION function
remains active until you click on the QUIT push button in the table.
It is important to note that the lines, arcs, and circles associated with a
region definition are not deleted or physically altered as a result of this
delete operation. However, they are no longer associated with this
region definition.
When you create a region after you delete a region, the new region will
be assigned the next sequential number. The old region numbers will
not be reused.
When you need to modify the drawing you must delete all regions.
Only after deleting the regions will you be able to modify the geometry.
Related Topics REGION

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--ENCLOSURE
Description The ENCLOSURE tool enables you to specify lines and arcs which will
make up an enclosure rather than solid elements of the model. An
enclosure may be used in a radiation problem where the enclosure may
represent the furnace. The enclosure may be assigned specific
properties in other components of PreCAST.
Method Activate the ENCLOSURE function by clicking on it.
The lines and arcs which define the enclosure may be selected by
dragging the cursor across them while holding down the left mouse
button. As a line or arc is selected it will change to red. Once a line or
arc has been selected release the mouse button. The letter E will be
displayed at the midpoint of each line/arc in the enclosure.
Continue selecting lines and/or arcs until the enclosure has been fully
described.
Remarks The ENCLOSURE function remains active until you select another tool
from the toolbox. All enclosure selections should be done at the same
time.
An enclosure is used for radiation view calculations.
Related Topics NONE

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--LINE
Description The LINE tool allows you to create a single line or a series of connected
lines. It is a toggle switch in the CREATE 2-D Toolbox.
Method Select the LINE tool by clicking the LINE push button in the Toolbox.
You may specify the two end points for a line by moving the cursor to
the desired locations in the drawing area and clicking the left mouse
button or you may type the X and Y coordinates in the coordinate input
boxes. You may also use a combination of these two methods to
specify the ends of the line to be drawn.
entered. A coordinate point, represented by a small green square, will
be drawn indicating the presence of the line point. Repeat the input
steps to provide the second point of the line to be drawn.
To draw continuous lines, move the cursor to each desired point and
click the left mouse button.
It is important to note that you must re-select the LINE tool in the
Toolbox to terminate the continuous lines and allow you to draw another
line or another set of continuous lines.
Remarks You may start or end a line on an existing point in the drawing area by
button.
You may delete an arc by using the DEL LINE-ARC tool.
Related Topics DEL LINE-ARC

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--MESH
Description MESH is a push button in the CREATE 2-D toolbox. It opens a table of
element dimensions.
Method Activate the MESH function by clicking the

MESH push button. The table of element
dimensions will be opened overlaying a
portion of the toolbox. This table will list each
region of the model. You may specify the
target length for the mesh elements in a
specific region of the model. If two regions
adjoin each other and have different lengths
for the mesh elements, the finer mesh density
will be used along the common edges.
To specify a length value, click on the desired

table entry. The background of the selected
table entry will change to red. At the same
time, the corresponding region of the model
will be highlighted in yellow in the drawing
area.
In the Edit Value input box, type the length you want PreCAST to use
as the target length for elements in this region of the model. When you
are satisfied with the value entered, press the ENTER key. This will
update the table entry and the next region in sequence will be
highlighted.
When you are satisfied with all table entries, click on the GEN MESH
push button in the table. This will open an
option list which will allow you to choose the
type, triangular or quadrilateral, of mesh which
will be generated.
Indicate your choice by moving the cursor over the desired mesh type
and click the left mouse button. This will result in the immediate
generation of the mesh.

GEOMETRY
Remarks Clicking on QUIT before a mesh is generated will result in creating the
prefix.geom file.
The time required to create the mesh depends on the element size
relative to the region, but is normally finished within a minute. While
the mesh is being generated, PreCAST displays a progress meter in the
lower portion of the drawing area.
When the mesh has been generated it will be displayed in the drawing
area, as shown here.
Note the two densities of mesh which were generated. These were
based upon the values in the table as described above.
CREATE 2-D can not generate any higher order mesh elements such
as quadratic.
Related Topics

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--MOVE
Description The MOVE tool allows you to move an existing point in the drawing
area. MOVE is a toggle button in the CREATE 2-D Toolbox. Lines
connected to the point which is moved will also be moved to maintain
their contact with the selected point.
Method Activate the MOVE function by clicking the MOVE push button. The
cursor icon will change to resemble a small bulls eye.
Move the cursor to the point you want to move and click either the left
or the middle mouse button. Move the cursor to the desired new
location and click the left or middle mouse button again.
Remarks The MOVE function remains active until you select another tool from
the toolbox.
MOVE will not work on points which are connected to arcs or points
which have been assigned to regions.
Related Topics LINE, ARC

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--QUIT
Description QUIT closes the CREATE 2-D drawing area and toolbox.QUIT is a push
button in the CREATE 2-D toolbox and results in an immediate action.
Method Activate QUIT by clicking on it.
Remarks If you press QUIT before a mesh has been generated it will be saved in
a prefix.geom file.
Clicking QUIT before a mesh is generated will result in creating the

prefix.geom file. The CREATE 2-D drawing area will be closed and the
meshed geometry will be displayed in the work window pane.
Related Topics MESH

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--REGION
Description The REGION tool enables you to assign lines and arcs to specific
regions of the model. These lines and arcs define the boundaries of a
region. A region may be assigned a specific material ID and other
properties in other components of PreCAST.
Method Activate the REGION function by clicking the REGION push button.
The lines and arcs which form the border of the region may be selected
by dragging the cursor across them while holding down the left mouse
button. As a line or arc is selected it will change to red. Once a line or
arc has been selected release the mouse button. You may select lines
and arcs which make up internal boundaries in the same manner.
Remarks Continue selecting lines and/or arcs until the region has been fully
enclosed. At that time, a region number will be automatically assigned.
These numbers will be displayed at the midpoint of each line/arc in the
region. You should include any inner borders of a region in that
regions selection. For example, if you were modeling a donut in 2-D,
the region of the donut would include the arcs forming the outside of the
donut and the arcs forming the outside of the donut hole.
Click on the REGION push button again to select lines and arcs to be
assigned to another region. Individual lines or arcs may be associated
with more than one region.
Related Topics DEL REGION

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--RESTORE
Description The RESTORE tool reads a 2-D geometry which has previously been
saved as a prefix.geom file. RESTORE is a push button in the
CREATE 2-D Toolbox which results in the immediate operation to read
the prefix.geom file and display the geometry in the drawing area.
Method Activate the RESTORE function by clicking on it. You may use any
arbitrary numbers to define the workspace. The model will
automatically scale the work area.
Remarks Prefix.geom files are created when you select the MESH tool or when
you QUIT CREATE 2-D.
Related Topics MESH, QUIT

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--REVERSE
Description The REVERSE tool allows you to switch the orientation of the last arc
created. As a result of the REVERSE tools action a concave arc can
be made convex and vice versa. REVERSE is a toggle switch in the
CREATE 2-D Toolbox.
Method Select the REVERSE tool by clicking the REVERSE push button in the
Toolbox.
Clicking the REVERSE push button results in the immediate action to

change the orientation of the arc.
Remarks Clicking the REVERSE push button again will change the arcs
orientation back to its original position.
You may click on the REVERSE push button at any time, however, it
will always change the orientation of the last arc you have drawn.
Related Topics ARC

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--SPLIT
Description The SPLIT tool enables you to create a new point at the intersection of
two lines or arcs. SPLIT is a push button in the CREATE 2-D toolbox.
Method Activate the SPLIT function by clicking the SPLIT push button.
Move the cursor across the desired intersection while holding down the
left mouse button. The two lines to be selected will change to yellow
when they have been selected.
Release the mouse button and the new point will appear.
Remarks You may split a line or arc in order to be able to remove either of the
resulting segments.
The SPLIT function remains active until you select another tool from
the toolbox.
Related Topics ARC, LINE, DEL LINE-ARC

GEOMETRY
GEOMETRY
CREATE 2-D--Toolbox--SMOOTH
Description The SMOOTH tool enables you to improve the quality of the mesh.
SMOOTH is a push button in the CREATE 2-D toolbox.
Method Activate the SMOOTH function by clicking the SMOOTH push button.
This results in the immediate action of improving the quality of the
mesh.
The improved mesh will be displayed in the drawing area.
Remarks SMOOTH improves the shape of the triangular or quadrilateral

elements in the mesh by adjusting the nodal locations. Each node is
placed at the center of the nodes immediately surrounding it.
The SMOOTH push button may be pressed several times until no

adjustment is detectable in the drawing area.
Related Topics MESH

GEOMETRY
GEOMETRY
SYMMETRY
Description SYMMETRY is a push button in the GEOMETRY menu. PreCAST

provides the capability to specify rotational and/or mirror symmetry for
radiation problems. SYMMETRY opens an option list sub-menu which
allows you to specify the symmetry properties for your model.
Method Activate SYMMETRY by clicking the

SYMMETRY push button. This results in an
immediate action to open the sub-menu
shown here.
The method and syntax for each of these

options will be described below. Each one
may be activated by clicking the left mouse
button when the cursor is over the respective
push button.
ROTATIONAL--specifies a symmetry in which a base object is

repeated, at evenly spaced intervals, around an axis of rotation.
Activating the ROTATIONAL option will open a dialog box as
shown.
In this dialog box you specify:

SECTORS--specifies the number of times the base object is to
be repeated around the axis of rotation.
Enter an integer value.
COORDINATES0 --one of two sets of coordinates which define

the axis of rotation.
COORDINATES1 --one of two sets of coordinates which define

the axis of rotation.
When you are satisfied with the values entered in the dialog
box, click on the APPLY push button.
You may click on the CANCEL push button at any time to

cancel this operation without setting or changing any values.

GEOMETRY
MIRROR 1--specifies a symmetry in which a plane of symmetry is used

to create a mirror image about the specified plane. Activating
the MIRROR 1 option will open a dialog box as shown.
In this dialog box you specify the coordinates of the three points
required to define a plane:
COORDINATES0 --one of three sets of coordinates which
define the plane of symmetry.


When you are satisfied with the values entered in the dialog
box, click on the APPLY push button.
You may click on the CANCEL push button at any time to

cancel this operation without setting or changing any values.
MIRROR 2--works in the same way as MIRROR 1 and allows you to

create two planes of mirror symmetry in the same problem.
EXECUTE--finds faces on the model which lie on the planes of

symmetry and includes them in a symmetry boundary condition
set.
QUIT--closes the option list box.
Remarks You may have one rotational symmetry and two planes of mirror
symmetry in the same problem. If there is only one plane of symmetry,
then you should input the data in MIRROR 1.
The symmetry properties are used for creating virtual images of an

object which will take part in the view factor calculations.
Related Topics

GEOMETRY
GEOMETRY
GRAVITY
Description GRAVITY is a push button in the GEOMETRY menu. PreCAST

provides the capability to specify the direction of gravitational pull on
the model. GRAVITY opens a dialog box which allows you to specify
the direction and units of measure for the gravitational factors affecting
your analysis. This is used in fluids and stress simulation problems.
Method Activate the GRAVITY function by clicking the GRAVITY push button.
This results in an immediate action displaying the dialog box shown
here.
The dialog box also contains

push buttons which may be
used to activate additional
gravity-related functions. The
method and syntax for each of
these functions and input
options will be described
below. Each one may be activated by clicking the left mouse button
when the cursor is over the respective push button.
X, Y and Z--are the components of the gravitational vector. To enter

the values, place the cursor in the appropriate input box and
type the desired value. You may move from one input box to
another using the cursor or by pressing the TAB key.
For example, in SI units, gravitational acceleration at the

earths surface is 9.8 meters/second2 in the downward direction.
If the Z axis in your model is pointing up, you would enter -9.8
for the Z component and leave the X and Y components at 0.0.
The default values for these components, in a 2-D problem are:

X = 0.0, Y = -9.8, and Z = 0.0. The default values in a 3-D
problem depend upon the model.
If the direction of gravity is at an angle, you must manually

calculate the x, y, and z component of the gravitational force.

GEOMETRY
UNITS--specifies the units of gravitational acceleration to be used for

this analysis. This push button is a rotary toggle switch.
Clicking on the UNITS toggle switch will cycle through the
optional units of acceleration. Your choices are:
{m/sec**2|cm/sec**2|mm/sec**2|ft/sec**2|in/sec**2}.
The default is m/sec**2.
When you are satisfied with the values you have entered, click
on the APPLY push button.
ROTATE--enables you to specify an axis of rotation and the angle of

rotation as a function of time. Activating the ROTATE option
will open the dialog boxes shown below.
AXIS OF ROTATION--use the dialog box to specify:

COORDINATES0 --one of two sets of coordinates which
define the axis of rotation.
COORDINATES1 --one of two sets of coordinates which
define the axis of rotation.
ANGLE VERSUS TIME FUNCTION--is defined in a dialog box

which is a two column table. In column one (Time) you
specify the elapsed time. In column two (Theta) you
specify the corresponding amount of rotation in
degrees.
At the top of column one in the table is a rotary toggle

button which may be used to set the units of time for
the table. Your choices for this unit of time are:
{sec|min}. Successive clicks on this push button will
toggle between these two units. The default is sec.

GEOMETRY
To enter values in the table:

(1) move the cursor to a position to the right of the
number one,
(2) click on the left mouse button. The first row and
column space will be highlighted in red.
(3) move the cursor to the Edit Value input box at the
bottom of the table,
(4) enter the desired value,
(5) press ENTER. The entered value will be placed in
the table and the cursor will automatically be
moved to the next available column and row
entry.
(6) Continue entering data as necessary by repeating
steps 4 and 5. You should have a minimum of
two table entries.
To change values in a table entry:

(1) move the cursor to the table entry to be changed,
(2) click on the left mouse button. The table entry will
be highlighted in red and its value will be
displayed in the Edit Value input box.
(3) move the cursor to the Edit Value input box at the
bottom of the table,
(5) press ENTER. The entered value will be placed in
the table and the cursor will automatically be
moved to the next available column and row
entry.
SAVE--When you are satisfied with the values entered in the

table, click on the SAVE push button at the top of the
table. This results in the immediate action to save the
Angle Versus Time Function table.

GEOMETRY
GRAPH--This push button results in the immediate action to

display a graph of the values in the Angle Versus Time
Function table. The following example is based upon
table data which was created for convenience of
illustration.
ERASE--this push button results in the immediate action to

erase the entire contents of the Angle Versus Time
Function Table.
QUIT--this push button results in closing the Angle Versus Time

Function dialog box. The dialog boxes are closed
without saving any data which may have been entered
or changed.
If you want to retain the data in the table, be sure to

click on the SAVE push button prior to using QUIT.
CANCEL--You may click on the CANCEL push button at any time to

close the GRAVITY function dialog boxes. This CANCEL
operation does not save or store any values.
APPLY--when you are satisfied with the values entered in the dialog
boxes, click on the APPLY push button. This results in the
immediate action to save the values you entered as a part of
this analysis.
Remarks The ROTATE capability of GRAVITY is typically used for tilt pouring
operations.
Related Topics

GEOMETRY
GEOMETRY
CENTRIFUGAL
Description CENTRIFUGAL is a push button in the GEOMETRY menu. It opens a

dialog box which allows you to specify an axis of rotation and an
angular velocity for your analysis. This is used in centrifugal casting
process problems.
Method Activate the CENTRIFUGAL function by clicking the CENTRIFUGAL

push button. This results in an immediate action to open the dialog box
and control panel shown here.
The control panel

contains push buttons
which may be used to
specify angular
velocity. The method
and syntax for each of
these functions and
input options will be
described below.
Each one may be
activated by clicking the left mouse button when the cursor is over the
respective push button.
In the dialog box, you enter the coordinates which describe the axis of
rotation.
COORDINATES0 --one of two sets of coordinates which define the axis
of rotation.
COORDINATES1 --one of two sets of coordinates which define the axis

of rotation.
To enter the values, place the cursor in the appropriate input

box and type the desired value. You may move from one input
box to another using the cursor or by pressing the TAB key.

GEOMETRY
CONSTANT--specifies a constant rate of rotation about the axis of

rotation. This push button opens a dialog box which allows you
to enter the constant and select
the time interval units. Enter the
constant rate of rotation in
radians.
At the top right-hand corner of the dialog box is a rotary toggle

button which may be used to set the time interval units. Your
choices for this unit of time are: {1/sec|1/min}. Successive
clicks on this push button will toggle between these two values.
The default is 1/sec.
TIME--enables you to specify an angular velocity which is a function of

time. When you click on the TIME push button a table will
open. You use this table to specify the time and angular
velocities for your analysis.
At the top of column one of this two-column table is a rotary

toggle button which may be used to set the units of time for the
table. Your choices for this
unit of time are: {sec|min}.
Successive clicks on this
push button will toggle
between these two units.
The default is sec.
At the top of column two is a

rotary toggle button which
may be used to set the units
of time angular velocity for
the table. Your choices for
this unit of time are:
{1/sec|1/min}. Successive
clicks on this push button will toggle between these two values.
The default is 1/sec.
In column one you specify the elapsed time. In column two you
specify the corresponding angular velocity in radians.
To enter values in the table:

(1) move the cursor to a position to the right of the number one,
(2) click on the left mouse button. The first row and column
space will be highlighted in red.
(3) move the cursor to the Edit Value input box at the bottom of
the table,

GEOMETRY
(5) press ENTER. The entered value will be placed in the table
and the cursor will automatically be moved to the next
available column and row entry.
(6) Continue entering data as necessary by repeating steps 4
and 5. You must have at least two table entries.
To change values in a table entry:

(1) move the cursor to the table entry to be changed,
(2) click on the left mouse button. The table entry will be
highlighted in red and its value will be displayed in the
Edit Value input box.
(3) move the cursor to the Edit Value input box at the bottom of
the table,
(5) press ENTER. The entered value will be placed in the table
and the cursor will automatically be moved to the next
available column and row entry.
SAVE--When you are satisfied with the values entered in the

table, click on the SAVE push button at the top of the
table. This results in the immediate action to save the
table.
GRAPH--This push button results in the immediate action to

display a graph of the values in the table. The
following example is based upon table data which was
created for convenience of illustration.
ERASE--this push button results in the immediate action to

erase the entire contents of the table.

GEOMETRY
QUIT--this push button results in closing the Time and Angular

Velocity dialog boxes. The dialog boxes are closed
without saving any data which may have been entered
or changed.
If you want to retain the data in the table, be sure to

click on the SAVE push button prior to using QUIT.
CANCEL--You may click on the CANCEL push button at any time to

close the GRAVITY function dialog boxes. This CANCEL
operation does not save or store any values.
APPLY--when you are satisfied with the values entered in the dialog
boxes, click on the APPLY push button. This results in the
immediate action to save the values you entered as a part of
this analysis.
Remarks ProCAST multiplies the CONSTANT value supplied times the Tabular
entries in the TIME/VELOCITY table, if any, to determine the angular
velocity.
Related Topics

GEOMETRY
GEOMETRY
CHECK GEOM
Description CHECK GEOM is a push button in the GEOMETRY menu. CHECK

GEOM opens an option list sub-menu. PreCAST provides the
capability to verify that all mesh elements have positive Jacobians, that
all surface elements have positive surface areas, and that all enclosure
elements have normals with the proper orientation. These checks are
important to further successful analysis of your model.
Method Activate the CHECK GEOM function by clicking the CHECK GEOM
push button. This results in an immediate
action to open the option list sub-menu
shown here.
The option list provides the capability to

examine specific aspects of your model.
The option list is a series of push buttons
corresponding to the type of check which
will be performed. The method and
syntax for each of these options will be
described below. Each one may be activated by clicking the left mouse
button when the cursor is over the respective push button.
NEG--JAC: checks the model to make

sure that all elements in the
model have positive Jacobians.
Elements with negative Jacobian
values are identified in a list. The
list is displayed on the right side
of the work window pane. An
example of the list is shown here.
To display negative Jacobian
elements graphically in the work
window pane, select an element
number and click on the SHOW
ELEMENT push button.
NEG-AREA: checks the model to make

sure that all surface elements in
the model have positive surface
areas. Elements with negative areas are identified in a list.
The list is displayed on the right side of the work window pane
and the negative surface areas are displayed graphically in the
work window pane. The list will be similar to the one shown
above for NEG-JAC elements. This test is only significant for
radiation models. View factors cannot be calculated for faces

GEOMETRY
that fail this test.
ENCLOSURE: checks the model to make sure that all of the enclosure
elements have normals with the proper orientation. Normal
orientation of all the enclosure elements is displayed
graphically in the work window pane. Additionally, five tools will
Tools for manipulating the orientation

of the enclosures normals.
These arrows indicate the direction of

the enclosures normals.
be displayed in the right margin. These tools allow you to

select specific enclosure elements and change the direction of
their normals. These tools are shown here and explained in the
following paragraphs.

GEOMETRY
SELECT: allows you to select individual elements for

manipulation. To activate this tool, click on the
SELECT push button. You may then choose the
element(s) by placing the cursor over them and
selecting them by pressing the left mouse button or you

may drag a selection box by pressing the right mouse
button and enclosing the desired elements.
When the elements have been selected they will

change color to red. In the example shown here,
elements have been selected.
DESELECT: allows you to deselect individual elements for

DESELECT push button. You may then choose the
element(s) by placing the cursor over them and
snagging them while pressing the left mouse button or
you may drag a selection box by pressing the right
mouse button and enclosing the desired elements.
When the elements have been deselected they will

change color to white.
SELECT ALL: allows you to select all elements for

SELECT ALL push button. When the elements have
been selected they will change color to red.

GEOMETRY
CANCEL: allows you to close the enclosure display. To

activate this option, click on the CANCEL push button.
This will result in the immediate action to close the
enclosure display.
REVERSE: allows you to reverse the direction of the normals

for the selected elements. To activate this tool, click on
the REVERSE push button. This will result in the

immediate action to change the direction of all and only
the elements which have been selected. For
convenience of illustration, in the figure shown here,
three elements have had the direction of their normals
reversed.

GEOMETRY
VOLUMES: calculates the volume of

each material region. The
calculation will be in cubic
centimeters. These material
volumes will be displayed in a
table at the right-side of the work
window pane. An example of the
table of material volumes is
shown here.
Remarks These diagnostic tools should be used to evaluate the quality of the
geometry and mesh. The quality of the geometry and mesh have a
direct bearing upon the eventual outcome of the simulation.
Related Topics

GEOMETRY
GEOMETRY
AXISYM
Description AXISYM is a toggle button in the GEOMETRY menu. AXISYM allows

you to specify the Y axis as the axis of symmetry. PreCAST provides
the capability to model 2-D axisymmetric problems.
Method Activate the AXISYM toggle button by clicking the AXISYM push button.
This results in an immediate action to change the color of the status
box.
Subsequent clicks on the AXISYM push button will toggle between

turning axisymmetry on and off.
Remarks When AXISYM is toggled to the on position, the Y axis is always taken
as an axis of symmetry and the X axis will point in the positive radial
direction.
You must have your model aligned at X = 0 for AXISYM to work.
Related Topics

GEOMETRY
GEOMETRY
VIRTUAL MOLD
Description VIRTUAL MOLD is a push button in the GEOMETRY menu. PreCAST

provides the capability to simulate a mold around the casting without
creating a geometry for the mold. This allows you to analyze the heat
conduction around the casting by mimicking the effect of a real mold.
Method Activate the VIRTUAL

MOLD function by
clicking the VIRTUAL
MOLD push button.
This results in an
immediate action to
open a dialog box
which enables you to
enter the minimum and maximum coordinates of the mold. The color
of the status box will also change.
As shown here, the dialog box consists of input lines where you may
specify the minimum and maximum values for each of the x, y, and z
coordinates of the mold.
The dialog box also contains three push buttons which perform the
specific actions described below. Each one may be activated by
clicking the respective push button.
APPLY: applies the minimum and maximum values entered, creates

the virtual mold, and closes the dialog box.
REMOVE: removes the coordinate values entered and closes the
dialog box. It also removes the virtual mold if it has been
created.
CANCEL: closes the dialog box.

GEOMETRY
Remarks VIRTUAL MOLD applies an analytical heat

conduction solution around the casting which mimics
the effect of a real mold. When minimum and
maximum coordinates have been specified and
applied, Pro-CAST computes a penetration depth for
each face of the casting that is within the virtual
box.
VIRTUAL MOLD adds a new material ID to the

model. You may assign mold properties to this new
material ID. Using the Interface component of
ProCAST, you may create and assign interface heat
transfer coefficients between the external faces of
the casting and the virtual mold.
The color legend, as shown in this figure, graphically

represents the resulting thermal depth or penetration
depths between the virtual mold and the casting.
Related Topics INTERFACE

MATERIALS
MATERIALS
Description MATERIALS is a push button in the Main Function Banner. This

function of PreCAST enables you to add materials and your own
material properties to the database. It also enables you to assign
specific materials to the model. When you activate the MATERIALS
push button, a menu is opened which will allow you to work with specific
properties for each material in the database. Selections from the menu
provide capabilities which will be discussed in this section.
Method MATERIALS is activated by clicking on it. The initial menu is shown

here. When you select a function from
this menu PreCAST will display
additional Dialog Boxes, Option Lists,
Data Input Windows, or sub-menus.
These graphical interface tools will guide
you through the process of specifying,
changing or deleting information about
the materials in the database.
You may leave the MATERIALS function

by clicking another push button in the Main Function Banner.
Remarks ProCAST provides the capability and flexibility to add, delete, or modify
a material in the material database. If you intend to use the material
data that comes with ProCAST, as is, you can proceed to the ASSIGN
function.
The major capabilities of the MATERIALS function of PreCAST will be

summarized here. Each capability will be described in greater detail in
this manual.
DATABASE
Provides the data management functions for the materials and
their respective properties in your database. DATABASE allows
you to add, delete, copy, and modify entries in the materials
database.
ASSIGN
Provides the capability to assign material properties to
elements in the model.
STRESS
Provides the data management and assign functions for stress
modeling material properties. Allows you to define a
mechanical model for the material.
MICRO

MATERIALS
Provides the data management and assign functions for micro

modeling material properties.
INVERSE
Inverse modeling will calculate selected material properties by
using the numerically generated thermal history and measured
temperatures. The inverse solver calculates the optimum
material property which will give the best match between the
measured and calculated cooling curves for the material. The
properties which may be determined using inverse modeling
are: Heat capacity, Thermal conductivity, and Latent heat.
When you select the STRESS or MICRO capabilities, another sub-

menu will be displayed. From this sub-menu you may select the
DATABASE or ASSIGN functions relating to either the stress or micro
properties of the material.
ProCASTs graphical user interface provides a straight forward and

simple procedure for working with the various databases used by
ProCAST. This database facility is described elsewhere in this manual.
You should read about this facility before attempting to modify the
materials database.
Related Topics DATABASE FACILITY, REGION

MATERIALS
MATERIALS
DATABASE
Description DATABASE is a push button in the MATERIALS menu which accesses

the Materials Database. Using ProCASTs DATABASE FACILITY you
may create, delete, or modify a material or its properties in the
materials database. These materials may then be used for simulation
and analysis.
Method DATABASE is activated by clicking on it. This results in the immediate

action to display a table containing any materials which may be in the
database. The figure shown here illustrates a display of the materials in
the Material
Database.
PreCAST allows you

to Read, Add, Copy,
and Delete materials
from the Materials
Database. These
capabilities are
described in the
DATABASE
FACILITY section of
this manual. You
should also refer to
the TABLE
MAINTENANCE
section of this
manual which
describes ProCASTs
graphical interface for maintaining tables.
This section will discuss the requirements for adding a material to the
database and how you specify individual properties and attributes for
that material.
To add a material to the database, click on the ADD push button in the
Material Database display. This will result in the immediate action to
open a blank Material Description which is shown below. Note that
PreCAST has entered the USER name and the DATE for you.

MATERIALS
The minimum requirement for adding a material to the database is to

give it a name and specify properties for the material. Individual
properties which may be required depend upon the type of modeling
and analysis to be done.
The syntax and options available for the Material Definition are
discussed below.
MATERIAL NAME: Enter the name you want to give the new material.
The material name must begin with an alphabetic character and may
include upper and lower case characters.
BASE: ProCAST will calculate material properties based upon the

material database which is supplied with it. To enter a base material,
place the cursor in the BASE input box and type one of the material
types supplied. You may choose from [ Al | Ni | Ti | Fe]. When you
have typed the base material to be used, click on the COMPOSITION
push button.

MATERIALS
COMPOSITION: This push button allows you to specify the alloy

composition to have ProCAST calculate the material properties. As
shown below, when you select this push button, a composition table will
be displayed. In this table you may enter the components of the alloy
and their weight percentage of the total alloy.
To enter the components of the alloy, place the cursor in the first
available input space in column one and type the elements symbol.
Then place the cursor in the column two input space adjacent to the
element and type the percentage of this element which is in the
compound. You may repeat this process for additional elements. You
may change an alloy or its corresponding percentage by placing the
cursor in the desired input line and re-typing the desired value.
When you are satisfied with the composition, click on the APPLY push
button. The composition will be highlighted as a reminder that data has
been entered.
You may close the composition table, without specifying the alloy
composition, by clicking the CANCEL push button. In the input box
labeled BASE, enter the base element of the alloy.

MATERIALS
PROPERTIES:
Properties are shown in four categories: THERMAL, FLUID, FILTER,
and ELECTROMAGNETIC. The properties which may be chosen
within each category are displayed as a group of check boxes or push
buttons. To specify a property, click the left mouse button when the
cursor is over the desired propertys check box. Selecting a property in
this manner will result in the immediate action to display an additional
dialog box or data input table.
Some properties may be described only as a constant value while

others may be described as a constant, a linear function or a quadratic
function. Based upon the individual property you select, ProCAST will
display the appropriate dialog or input table.
The simplest of these input boxes is similar to the one shown here and
may contain a rotary toggle switch for the units of measure and a text
input line. Select the
desired units of
measure by clicking
on the UNITS push
button. Successive
clicks on this push
button will toggle through the available options. To enter the desired
value for this property or attribute move the cursor to the text input line
and type the value. When you click on the APPLY push button, the
data entered will be stored, the dialog box will be closed, and the
propertys check box on the Material Definition display will be
highlighted in light blue.
You may click on the CANCEL push button to close the dialog box
without saving the data.
For those properties which may also be described as linear or quadratic

functions, ProCAST will
display an option box from
which you may choose to use
a CONSTANT, LINEAR, or
QUADRATIC function. An example of this option box is shown here.
Selecting the CONSTANT option will display a dialog box similar to the
one described in the preceding paragraphs.
Selecting the LINEAR option will result in the immediate action to

display an input table. This table, like the dialog box for a constant,
may contain rotary toggle switches for the units of measure. As shown
in this example for Conductivity, there are two toggle switches which
also serve as the column sub-headings for the table.

MATERIALS
Select the desired units of measure by clicking on the column heading

push buttons. Successive clicks on these push buttons will toggle
through the available
options. To enter a
table value, select
the first or next
available table entry,
move the cursor to
the text input line,
type the value, and
Rotary Toggle
press the ENTER key. Switches
This will place the
value in the table and
move the cursor to
the next available
table entry. When
you are satisfied with
the table entries, click
on the STORE push
button, the data in
the table will be
stored, the dialog box
will be closed, and
the propertys check box on the Material Definition display will be
highlighted in light blue.
You may click on the GRAPH push button to display a graph of the
function. You may click on the ERASE push button to erase the entire
contents of the table. You may click on the CANCEL push button to
close the dialog box without saving the data.
Selecting the
QUADRATIC option
will result in the
immediate action to
display an input
table. In this table,
column sub-headings
may act like the
rotary toggle switches
for the units of
measure. As shown
in the following
example, there are
two column sub-
heading toggle
switches.
Select the desired

MATERIALS
units of measure by clicking on the column sub-heading push buttons.

Successive clicks on these push buttons will toggle through the
available options. To enter a table value, select the first or next
available table entry, move the cursor to the text input line, type the
value, and press the ENTER key. This will place the value in the table
and move the cursor to the next available table entry. When you are
satisfied with the table entries, click on the STORE push button, the
table data will be stored, the dialog box will be closed and the propertys
check box on the Material Definition display will be highlighted in light
blue.
The GRAPH, ERASE, and CANCEL push buttons function in the same
way as described in the paragraphs above.
The syntax options for Material Properties will be presented below.
THERMAL PROPERTIES
CONDUCTIVITY--may be specified as a constant, a linear function or a
quadratic function.
Constant: Select the units from the following choices: {W/m/K |
cal/cm/C/sec | Btu/ft/F/sec | cal/cm/C/min | Btu/ft/F/min
| cal/mm/C/sec | Btu/in/F/sec | Btu/in/F/min}
Enter the constant value to be used in the Edit Value

input line.
Linear function: Select the Temperature from: {C | F | R | K}

Select the Conductivity units from: {W/m/K |
Enter the temperatures in column one and Conductivity

values in column two.
Quadratic function: Select the Temperature from: {C | F | R |

K}
Select the Conductivity units from: {W/m/K |
Enter the temperatures in column one, the constant

coefficient in column two, the coefficient of temperature
in column three, and the coefficient of temperature
squared in column four.
DENSITY--may be specified as a constant, a linear function or a

quadratic function.
Constant: Select the units from the following choices: {kg/m**3

MATERIALS
| g/cc | g/mm**3 | lb/ft**3 | lb/in**3}

input line.

Select the Density units from: {kg/m**3 | g/cc |
g/mm**3 | lb/ft**3 | lb/in**3}
Enter the temperatures in column one and Density


K}
Select the Density units from: {k/m**3 | g/cc | g/mm**3
| lb/ft**3 | lb/in**3}


MATERIALS
SPECIFIC HEAT--may be specified as a constant, a linear function or a

quadratic function.
Constant: Select the units from the following choices: {kJ/kg/K |
cal/g/C | Btu/lb/F}

input line.

Select the Specific Heat units from: {kJ/kg/K | cal/g/C |
Btu/lb/F}
Enter the temperatures in column one and Specific

Heat values in column two.

K}
Select the Specific Heat units from: {kJ/kg/K | cal/g/C |
Btu/lb/F}

ENTHALPY--may be specified as a linear function or a quadratic

function.
Select the Enthalpy units from: {kJ/kg | cal/g | Btu/lb}
Enter the temperatures in column one and Enthalpy


K}
Select the Enthalpy units from: {kJ/kg | cal/g | Btu/lb}


MATERIALS
FRACTION SOLID--may be specified as a linear function or a quadratic

function.
Enter the temperatures in column one and Fraction
Solid values in column two.

K}
CALC SOLID PATH--this push button results in the immediate action to

open a sub-menu which allows you to choose either SCHEIL or
LEVER. As shown here, this sub-
menu consists of two push buttons.
Note: The CALC SOLID PATH

capability will not be implemented
until a release of ProCAST subsequent to 3.1.0.
SOLIDUS--is specified as a constant.

Constant: Select the Temperature from: {C | F | R | K}

input line.
LIQUIDUS--is specified as a constant.


input line.
LATENT HEAT--is specified as a constant.

Constant: Select the units from: {kJ/kg | cal/g | Btu/lb}

input line.

MATERIALS
FLUID PROPERTIES
VISCOSITY may be specified as Newtonian or Non-Newtonian. When
you select
the
VISCOSIT
Y property
check box,
an option
menu will
be displayed. As shown in this figure, the option menu consists
of two push buttons.
NEWTONIAN--Select Newtonian by clicking the NEWTONIAN

push button. This will display an option menu from
which you may elect to describe the materials viscosity
as a constant, linear function or quadratic function.
Constant: Select the units from the following choices:
{Pa.s | N.s/m**2 | centipoise | poise | lb/s/ft |
lb/min/ft | lb/hr/ft}
Enter the constant value to be used in the Edit

Value input line.
Linear function: Select the Temperature from: {C | F |

R | K}
Select the Viscosity units from: {Pa.s |
N.s/m**2 | centipoise | poise | lb/s/ft | lb/min/ft |
lb/hr/ft}
Enter the temperatures in column one and

Viscosity values in column two.
Quadratic function: Select the Temperature from: {C |

F | R | K}
N.s/m**2 | centipoise | poise | lb/s/ft | lb/min/ft |
lb/hr/ft}
Enter the temperatures in column one, the

constant coefficient in column two, the
coefficient of temperature in column three, and
the coefficient of temperature squared in
column four.

MATERIALS
CARREAU-YASUDA--Select Carreau-Yasuda by clicking on it.

This will display a menu which will allow you to describe
the viscosity. This menu is shown here. You select the
method by clicking the desired methods push button.
Non-Newtonian values may be described as constants
or as linear functions. This method is described in
Equation C.7.2 in Appendix C.
ZERO VISCOSITY
Constant: Select the units from the following
choices: {Pa.s | N.s/m**2 | centipoise |
poise | lb/s/ft | lb/min/ft | lb/hr/ft}
Enter the constant value to be used in

the Edit Value input line.
Linear function: Select the Temperature from:

{C | F | R | K}
N.s/m**2 | centipoise | poise | lb/s/ft |
Enter the temperatures in column one

and Viscosity values in column two.
INFINITE VISCOSITY


{C | F | R | K}


MATERIALS
PHASE SHIFT
Constant: The units are sec/min
{C | F | R | K}
The Viscosity units are sec/min

POWER
Constant: Enter the constant value to be used
in the Edit Value input line.
{C | F | R | K}

YASUDA
{C | F | R | K}


MATERIALS
POWER-CUTOFF--Select Power-Cutoff by clicking on it. This

will display a menu which will allow you to describe the
viscosity. This menu is shown here. You select the
method by clicking the on the desired methods push
button. Power-Cutoff values may be described as
constants or as linear functions.
ZERO VISCOSITY


{C | F | R | K}

K FACTOR
choices: {sec | min}


{C | F | R | K}
Select the Phase Shift units from: {sec
| min}

and Phase Shift values in column two.

MATERIALS
POWER
{C | F | R | K}

and Power values in column two.
SURFACE TENSION--may be specified as a constant, a linear function

or a quadratic function.
Constant: Select the units from the following choices: {N/m |
dyne/cm | lb/ft | lb/in}

input line.

Select the Surface Tension units from: {N/m | dyne/cm
| lb/ft | lb/in}
Enter the temperatures in column one and Surface

Tension values in column two.

K}
Select the Surface Tension units from: {N/m | dyne/cm
| lb/ft | lb/in}


MATERIALS
PERMEABILITY--may be specified as a constant, a linear function or a

quadratic function. If you provide this data, it will override permeability
data developed internally by ProCAST.
Constant: Select the units from the following choices: {m**2 |
cm**2 | mm**2 | ft**2 | in**2}

input line.

Select the Permeability units from: {m**2 | cm**2 |
mm**2 | ft**2 | in**2}
Enter the temperatures in column one and Permeability


K}
Select the Permeability units from: {m**2 | cm**2 |
mm**2 | ft**2 | in**2}

FILTER PROPERTIES
VOID FRACTION--is specified as a constant.
Constant: Enter the constant value to be used in the Edit Value
input line.
SURFACE AREA--is specified as a constant. This specifies the surface

area to volume ratio.
Constant: Select the units from: {1/m | 1/cm | 1/mm | 1/ft | 1/in}

input line.

MATERIALS
ELECTROMAGNETIC PROPERTIES
PERMEABILITY--refers to magnetic permeability and may be specified
as a constant, a linear function or a quadratic function.
Constant: Select the units from the following choices: {henry/m
| henry/cm | henry/mm | henry/ft | henry/in}

input line.

Select the Permeability units from: {henry/m |
henry/cm | henry/mm | henry/ft | henry/in}
Enter the temperatures in column one and Permeability


K}
Select the Permeability units from: {henry/m |
henry/cm | henry/mm | henry/ft | henry/in}


MATERIALS
CONDUCTIVITYrefers to electrical conductivity and may be specified

as a constant, a linear function or a quadratic function.
Constant: Select the units from the following choices: {ohm-m |
ohm-cm | ohm-mm | ohm-ft | ohm-in}

input line.

Select the Conductivity units from: {ohm-m | ohm-cm |
ohm-mm | ohm-ft | ohm-in}
Enter the temperatures in column one and Conductivity


K}
Select the Conductivity units from: {ohm-m | ohm-cm |
ohm-mm | ohm-ft | ohm-in}

COMMENTS: This portion of the Material Description is a free format

text box which may be used to annotate the material. For
example, you may want to describe the sources for any
property data or techniques used to develop the material or its
properties.
Remarks The minimum requirements for the specific properties of a material

which must be provided depend upon the type of analysis you are going
to perform. The minimums for six general types of analysis are
outlined here.
1. Thermal analysis--Conductivity, Density, and Specific Heat.
2. Fluid (only)--Density and Viscosity.
3. Fluid-Thermal flow analysis--Conductivity, Density, Specific Heat,
and Viscosity.
4. Thermal and fluids coupled, with phase change--Conductivity,
Density, Liquidus, Solidus, Specific Heat, and Viscosity.
5. Stress--Conductivity, Density, Liquidus, Solidus, Youngs Modulus,
Thermal Expansion Coefficient, Poissons Ration, Density, and
Specific Heat.
6. Induction heating--Magnetic Permeability and Electrical
Conductivity.
For a material undergoing phase change, there are three ways to

MATERIALS
account for the latent heat of fusion.

1. Modified specific heat function. This involves converting the latent
heat into an equivalent specific heat spike over the freezing
range.
2. A continuous enthalpy function can be generated by integrating the
specific heat over temperature along with the latent heat. If
such a function is specified, it will take precedence over the
specific heat.
3. A user specified latent heat value many be used along with a
fraction solid curve and the specific heat, and ProCAST will
automatically compute an enthalpy curve.
The values of the liquidus and solidus temperature are used in a fluids
analysis to determine when the material is in the mushy freezing range.
A transition is made then to a DArcy type flow solution, i.e., porous
media flow, rather than a full Navier-Stokes flow. If you are performing
a thermal only solution, the liquidus and solidus temperatures have no
effect.
If you describe a property by entering data as a linear function of

temperature table and save the table, the linear function will override
any value, for this property, which was specified in the constant window.
If you describe a property by entering data as a piecewise quadratic
function of temperature table and save the table, the quadratic function
will override any value, for this property, which was specified in the
constant window or as a linear function.
The form of the quadratic function is F = A + BT + CT2. The

temperature value for each row indicates the beginning of the range of
applicability. There must be at least two rows filled out for the function
to be graphed. The temperature from the last row is used as the upper
bound for the function. The A, B, and C values of the last row are
ignored and can be left blank. When a piecewise quadratic property
function with multiple intervals is used in ProCAST, the function is
searched from the highest temperature downwards to find the correct
temperature interval.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE

MATERIALS
MATERIALS
ASSIGN
Description ASSIGN is a push button in the MATERIALS menu. It provides the

capability to associate properties from the database with element IDs in
the model.
Method ASSIGN is activated by clicking on it. This results in the immediate

action to display a table containing a list of the material regions which
have been defined in the model. It also displays a table of the
materials in the
materials database.
The figure shown
here illustrates a
display for a model
with two Material
Regions and the
Operate
Material Database as Rotary
entries. Toggle
Switches
The background of Toggle Switches
each Region ID#, Time Step Update

shown in column one Frequency
of this table, is
displayed in a
different color. When
you select an entry
from this table by
clicking on the ID#,
the elements in the
model with a
corresponding ID
number will be drawn
in the work window
pane in the same
color as its respective
table entry. You may
also click in the
second column
without redrawing the
mesh.

MATERIALS
To assign a material to a region of the model:

1. Select the region by clicking the left mouse button when the cursor is
over the desired table entry.
2. Select a material from the database by moving the cursor down to
the window displaying the MATERIAL DATABASE entries. If
the material you want is not visible in the table at first, you may
scroll to the desired entry.
3. When you have located the desired material entry, click on it.
4. ASSIGN the material to the region by clicking the ASSIGN push
button. This will place the material name in column two of the
Assignment Table.
To associate materials with other regions, repeat steps one through

four.
In addition to associating materials with elements, ASSIGN provides

the capability to further define how each material is to be used in the
simulation. These definitions are indicated in columns three, four, and
five and represent TYPE, MOLD, and UPDATE respectively.
TYPE may contain one of four possible values. The entry in column
three, titled T, of each row is a rotary toggle switch. Successive
clicks on the contents of this column will cycle through the
possible choices. Valid material types are: T Thermal, F Fluid,
I Filter, and O Foam.
When you change this setting, PreCAST checks the database

to make sure that you have defined the properties required to
satisfy the TYPE designation you have specified.
Select the type of material from the following choices: {T | F | I |

O}.
MOLD may contain Yes or No to indicate that this material is part of the
mold. The entry in column four, titled M, of each row is a
toggle switch. Successive clicks on the contents of this column
will switch between the Y and N values.

MATERIALS
UPDATE may contain a value to indicate the time step frequency for
integrating the finite element matrices. By default this is done
at every time step. However, if the material properties vary
slowly with temperature, as they typically do with molds, you
may wish to recompute the matrices much less frequently. This
saves a considerable amount of CPU time.
Select a row from the Assignment table by clicking the left

mouse button when the cursor is over the desired entry. Move
the cursor to the Edit Value text input line. Type the numerical
value to indicate the desired time step frequency and press
ENTER. This will place the entered value in column five, titled
U, of the selected row.
When you are satisfied with the assignments and their T, M and U
settings, click on the QUIT push button in the Material Assignment table
or click on a push button in the Main Function Banner. This will store
the assignments and close the display.
Remarks The letter shown in column two, before a material name, in the Material
Database display indicates that the minimum required properties have
been defined for this material to be used in specific types of
simulations.
The letter F indicates that the material has the minimum
required properties for a fluids simulation.
The letter T signifies that the minimum requirements for a
thermal only analysis are satisfied.
An asterisk * shows that there is insufficient data for the

material to be used in any type of simulation, except a
fluid only simulation. If you are performing a fluid only
analysis and this column is marked with an asterisk,
you should verify that the Density and Viscosity have
been specified for the material.
In practice, all non-fluid regions of the model should be specified as the

mold. This is particularly true if the simulation is to encompass a
number of casting cycles such as in die casting or permanent mold
casting. The material IDs which constitute the mold should be indicated
with a Y.

MATERIALS
You may examine and/or modify the material properties for Material
Database entries by clicking the READ/MODIFY push button in the
Material Database display window. This will display the Material
Description Display as shown here.
Further use of this capability is explained in the MATERIALS

DATABASE section of this manual.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE, MATERIALS

DATABASE

MATERIALS
MATERIALS
STRESS
Description STRESS is a push button in the MATERIALS menu. It provides the

capability, through a sub-menu, to access the Stress Model Database
and to associate stress model characteristics from the database with
element IDs in the model. Using ProCASTs DATABASE FACILITY
you may create, delete, or modify a stress model or its properties in the
database. These stress models may then be used for simulation and
analysis.
Method STRESS is activated by clicking on it. This results in the immediate

action to display a sub-menu. As
shown here, you may then choose to
access the stress model database or
proceed to the assign function.
PreCAST allows you to Read, Add,

Copy, and Delete materials from the
Materials Database. These
capabilities are described in the DATABASE FACILITY section of this
manual. You should also refer to the TABLE MAINTENANCE section
of this manual which describes ProCASTs graphical interface for
maintaining tables.
This section will discuss the requirements for adding a stress model to
the database and how you specify individual properties and attributes
for that model. This section will also discuss how you associate
elements in your model with the stress database entries using the
assign function.
You select from the

sub-menu by clicking
on the desired
function. When you
click on the
DATABASE push
button in the sub-
menu, it results in the
immediate action to
display a table
containing any stress
models which may be
in the database. The
figure shown here
illustrates a display of
the models in the

MATERIALS
Stress Database.
To add a stress mechanical model to the database, click on the ADD

push button in the Stress Database display. This will result in the
immediate action to open a blank Stress Description which is shown
below. Note that PreCAST has entered the USER name and the DATE
for you.
The minimum requirement for adding a stress model to the database is

to give it a name and define its properties. The individual properties
required depends upon the type of material selected and the modeling
and analysis to be done.
The syntax and options available for the Stress Definition are discussed
below.
MATERIAL NAME: Enter the name you want to give the new material.
The material name must begin with an alphabetic character and may
include upper and lower case characters.

MATERIALS
MATERIAL TYPE: Select the type of material you are adding.

ProCAST displays the MATERIAL TYPE as a rotary toggle button.
Successive clicks on this push button will cycle through the available
choices. The available choices are:
LINEAR ELASTIC
PLASTIC, LINEAR HARDENING
PLASTIC, POWER LAW HARDENING
VISCOPLASTIC 1, LINEAR HARDENING
VISCOPLASTIC 1, POWER LAW HARDENING
VISCOPLASTIC 2, LINEAR HARDENING
VISCOPLASTIC 2, POWER LAW HARDENING
PROPERTIES:
Properties are displayed as a group of check boxes or push buttons. To
specify a property, click on the desired propertys check box. Selecting
a property in this manner will result in
the immediate action to display an
additional option menu which will
allow you to describe the property as
either a CONSTANT or as a LINEAR function. This option menu is
shown here.
Properties which are not applicable to a specific material type will be

shaded dark red. This is illustrated in the figure above, the FLUIDITY,
YIELD STRESS, HARDENING PARAM., and VISOPLASTIC FLOW
POTENTIAL properties are not applicable for the LINEAR ELASTIC
material type. Additionally, ProCAST dynamically displays property
names based upon the material type option you have selected.
If you select the CONSTANT option, an input box similar to the one
shown here will be displayed. It will contain a text input line and may
contain a rotary
toggle switch for the
units of measure.
Successive clicks on
this push button will
toggle through the
available options. To enter the desired value for this property or
attribute move the cursor to the text input line and type the value.
When you click on the APPLY push button, the data entered will be
stored, the dialog box will be closed, and the propertys check box on
the Stress Definition display will be highlighted in light blue.

MATERIALS
Selecting the LINEAR option will result in the immediate action to

display an input table. This table, like the dialog box for a constant,
may contain rotary toggle switches for the units of measure. As shown
in this example for Elastic Modulus, there are two toggle switches which
also serve as the column sub-headings for the table.
Select the desired

units of measure by
clicking on the
column heading push
buttons. Successive
clicks on these push
buttons will toggle
through the available
options. To enter a
table value, select
the first or next
available table entry,
move the cursor to
the text input line,
type the value, and
press the ENTER key.
This will place the
value in the table and
move the cursor to
the next available
table entry. When
you are satisfied with the table entries, click on the STORE push button,
the data in the table will be stored, the dialog box will be closed, and the
propertys check box on the Stress Definition display will be highlighted
in light blue.
The syntax options for Stress Properties will be presented below. For
convenience of presentation, all of the properties will be described here.
In practice, ProCAST will only display those properties which are valid
for each material type.

MATERIALS
ELASTIC MODULUS
Constant: Select the units from the following choices: {N/m**2 |
Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi |
lb/ft**2}

input line.

Select the Elastic Modulus units from: {N/m**2 | Pa |
KPa | MPa | bar | dyne/cm**2 | atm | psia |Ksi | lb/ft**2}
Enter the temperatures in column one and Elastic

Modulus values in column two.
FLUIDITY
Constant: Select the units from the following choices: {1/sec |
1/min}
Select the Fluidity units from: {1/sec | 1/min}
Enter the temperatures in column one and Fluidity

HARDENING EXPONENT
input line.
Enter the temperatures in column one and Hardening

Data values in column two.
HARDENING PARAMETER
lb/ft**2}

input line.
Select the Hardening Data units from: {N/m**2 | Pa |
Enter the temperatures in column one and Hardening


MATERIALS
POISSONS RATIO
input line.
Enter the temperatures in column one and Poissons
Ratio values in column two.
STRENGTH PARAMETER
lb/ft**2}

input line.

Select the Yield/Strength units from: {N/m**2 | Pa |
Enter the temperatures in column one and the

Yield/Strength values in column two.
THERMAL EXPANSION
Constant: Select the units from the following choices: {1/K |
1/C | 1/F | 1/R}

input line.

Select the Thermal Coefficient units from: {1/K | 1/C |
1/F | 1/R}
Enter the temperatures in column one and Thermal

Coefficient values in column two.
VISCOPLASTIC FLOW POTENTIAL

input line.
Enter the temperatures in column one and Visco

Potential values in column two.

MATERIALS
YIELD STRESS
lb/ft**2}

input line.

Select the Yield/Strength units from: {N/m**2 | Pa |
Enter the temperatures in column one and

Yield/Strength values in column two.
COMMENTS: This portion of the Stress Description is a free format text

box which may be used to annotate the material. For example,
you may want to describe the sources for any property data or
techniques used to develop the stress model or its properties.

MATERIALS
ASSIGN is a push button in the STRESS sub-menu. It provides the

capability to associate properties from the database with element IDs in
the model.
ASSIGN is activated by clicking on it. This results in the immediate

materials in the
materials database.
The figure shown
here illustrates a
display for a model
with two Material
Regions and the
Material Database
entries.
The background of
each Region ID#,
shown in column one
of this table, is
displayed in a
different color. When
you select an entry
from this table by
clicking on the ID#,
the elements in the
model with a
corresponding ID
in the work window
pane in the same
color as its respective
table entry.

MATERIALS
To assign a stress model to a region of the model:

1. Select the region by clicking on the desired table entry.
2. Select a stress model from the database by moving the cursor down
to the window displaying the MATERIAL DATABASE entries. If
the material you want is not visible in the table at first, you may
3. When you have located the desired material entry, click on it.
button. This will place the material name in column two of the
Assignment Table.
To associate stress models with other regions, repeat steps one
through four.
When you are satisfied with the assignments, click on the QUIT push
button in the Assignment table. This will store the assignments and
close the display. You may close this display without storing any values
by clicking the CANCEL push button.
Remarks If no assignment is made for a material, it will be taken as perfectly rigid

in the stress analysis.
The use of mechanical model data is discussed in the Mathematical

Formulations section of this manual.
If you describe a property by entering data as a linear function of

temperature table and save the table, the linear function will override
any value, for this property, which was specified in the constant window.
You may examine

and/or modify the
Stress Model
properties for
Material Database
entries by clicking the
READ/MODIFY push
button in the Material
Database display
window. This will
display the Material
Description Display
as shown here.

DATABASE

MATERIALS
MATERIALS
MICRO
Description MICRO is a push button in the MATERIALS menu. It provides the

capability, through a sub-menu, to access the Micro Model Database
and to associate micro model characteristics from the database with
material IDs in the model. Using ProCASTs DATABASE FACILITY
you may create, delete, or modify a micro model or its properties in the
database. These micro models may then be used for simulation and
analysis.
Method MICRO is activated by clicking on it. This results in the immediate

action to display a sub-menu. As
shown here, you may then choose to
access the micro model database or
proceed to the assign function.
ProCAST allows you to Read, Add,

Copy, and Delete micro models from
the database. These capabilities are
described in the DATABASE FACILITY section of this manual. You
should also refer to the TABLE MAINTENANCE section of this manual
which describes ProCASTs graphical interface for maintaining tables.
This section will discuss the requirements for adding a micro model to
the database and how you specify individual properties and attributes
for that model. This section will also discuss how you associate
elements in your model with the micro database entries using the
assign function.
You select from the sub-menu by clicking on the desired function.
When you click on

the DATABASE
push button in the
sub-menu, it results
in the immediate
action to display a
table containing any
micro models which
may be in the
database. The
figure shown here
illustrates this table
display, in this
case, there are no
models in the Micro

MATERIALS
Database.
To add a micro model to the database, click on the ADD push button in
the Micro Database display. This will result in the immediate action to
open a sub-menu, as
shown here, which
lists the types of
micro models which
may be defined.
The characteristics,
input parameters,
and options which are
available or required
vary from one micro
model to another.
When you choose

from this menu,
ProCAST will display
the appropriate input
form and options in a blank Micro Description which is shown below.
For convenience of illustration, the example shown is the result of
selecting the EQUIAXED DENDRITE option from the sub-menu.
Input Text
Line
Rotary
Toggle
Switch
Property
Check Box
Note that PreCAST has entered the USER name and the DATE for you.

MATERIALS
PreCAST has also entered, as a default, the KEYWORD which is the

same as the file prefix you entered when you started PreCAST. The
minimum requirement for adding a micro model to the database is to
give it a keyword name and enter values for input parameters.
All of the micro model descriptions have two input text lines in
common: KEYWORD and COMMENTS. Specific other properties
which may be required, depend upon the type of micro model selected
and the types of materials to which this model is to be applied.
The syntax for the common entries are described below. Following
these descriptions, the individual options for each available micro
model are discussed.
KEYWORD: Enter the name you want to give the micro model
database entry. The key word must begin with an alphabetic character.
COMMENTS: This portion of the Micro Description is a free format text

box which may be used to annotate the material. For example, you
may want to describe the sources for any property data or techniques
used to develop the micro model or its properties.
PROPERTIES: Properties are displayed as a group of check boxes,

push buttons, text input lines, or a combination of these. This is
illustrated in the figure shown above for the Equiaxed Dendrite model.
To enter data in a text input line, place the cursor in the text box, type
the desired data, and press ENTER. In some cases, the text input line
will be accompanied by a rotary toggle switch. These toggle switches
allow you to choose the desired value, usually a unit of measure, from a
list of options. As shown in the example above, there are optional units
of measure for the GIBBS-THOMPSON COEFFICIENT. Successive
clicks on the toggle switch will cycle through the available options for
units.
To specify a property which is displayed in a check box, click on the

desired propertys check box. This will result in the immediate action to
display an additional option menu or
a input dialog box. Some properties
may be specified either as constants
or as a linear function. An option menu, similar to the one shown here,
will allow you to describe the property as either a CONSTANT or as a
function of COOLING RATE, TEMPERATURE, or COMPOSITION.
ProCAST dynamically displays the appropriate property names, option

boxes, and input text lines based upon the type of micro model option
you select.

MATERIALS
shown here will be displayed. It will contain a text input line. When a
property requires
that you specify the
units for the
property, a rotary
toggle switch will be
displayed in the
input box. Successive clicks on this push button will toggle through the
When you click on the APPLY push button, the data entered will be
stored, the dialog box will be closed, and the propertys check box on
the Micro Definition display will be highlighted in light blue.
You may click on the

CANCEL push button
to close the dialog
box without saving
the data.
Selecting the
COOLING RATE,
TEMPERATURE, or
COMPOSITION
option will result in
the immediate action
to display an input
table. This table, like
the dialog box for a
constant, may
contain rotary toggle
switches for the units
of measure. As
shown in this
example for Transformation Temperature, there are two toggle switches
which also serve as the column sub-headings for the table.

through the available options.
To enter a table value, select the first or next available table entry,
move the cursor to the text input line, type the value, and press the
ENTER key. This will place the value in the table and highlight the next
available table entry. When you are satisfied with the table entries,
click on the SAVE push button, the data in the table will be stored, the
dialog box will be closed, and the propertys check box on the Micro

MATERIALS
Definition display will be highlighted in light blue.
The syntax and options for Micro Model Properties will be presented
below. For convenience of presentation, the micro models are
presented in alphabetical order.

MATERIALS
CAFE MODEL
Editors Note: The CAFE capability has not yet been implemented in ProCAST.
AVERAGE UNDERCOOLING
Editors Note: discussion to be added.
Constant: Enter the constant value to be used in the input line.
GROWTH COEFFICIENT 1 and 2

MAX NUCLEATION SITES
STD DEVIATION

MATERIALS
COUPLED EUTECTIC
The Coupled Eutectic Growth Models are divided into two categories:
Instantaneous Nucleation and
Continuous Nucleation.
Selecting the COUPLED
EUTECTIC model results in
opening another sub-menu
which provides you with the option to specify either instantaneous or
continuous nucleation. This sub-menu is shown here. You select the
desired option by clicking the appropriate push button. These models
can be applicable to both regular and irregular eutectics. These models
also address the growth of both the stable and metastable eutectic.
Either selection will result in displaying the input form shown here. The
only difference is that the SUBSTRATE DENSITY is given as a function
of temperature instead of cooling rate in the CONTINUOUS
NUCLEATION model.
In the case of
continuous
nucleation,
nucleation begins at
the specified
nucleation
temperature and
continues until the
maximum
undercooling point in
the cooling curve is
reached. Once
nucleated, the nuclei
keep on growing.
Beyond the point of
maximum
undercooling,
nucleation ceases
and the growth
process becomes more dominant and the cooling curve shows
recalescence.
For instantaneous nucleation, you specify the substrate density as a

fraction of cooling rate with the assumption that nucleation occurs at a
unique temperature instantaneously.

MATERIALS
CRITICAL COOLING RATE is the rate at which you get the stable-to-
metastable eutectic transition. For a given melt chemistry, this
can be obtained from simple experiments.
You should enter the absolute value of the cooling rate. If you
are using this model for stable eutectic growth only, then enter
a very high value for the critical cooling rate parameter. This
will avoid any formation of metastable eutectic.
Constant: Select the Cooling Rate units from the following

choices: {K/sec | F/sec | C/sec | R/sec | K/min | F/min |
C/min | R/min}
Enter the constant value to be used in the input line.
LAMELLAR SPACING is used for modeling the growth of metastable

eutectic. These data must be obtained from experiment. With
increasing cooling rate, the lamellar spacing is expected to
decrease.
Linear function: Select the Cooling Rate units from: {K/sec |

F/sec | C/sec | R/sec | K/min | F/min | C/min | R/min}
Select the Lamellar spacing units from: {m | cm | mm |
ft | in}
Enter the cooling rate values in column one and

Lamellar spacing values in column two.
METASTABLE GROWTH CONSTANT

Constant: Select the units from: {m/sec/K**2 | cm/sec/K**2 |
mm/sec/K**2 | ft/sec/F**2 | in/sec/F**2 | m/min/K**2 |
cm/min/K**2 | mm/min/K**2 | ft/min/F**2 | in/min/F**2}
PARTITION COEFFICIENT gives the ratio of solute content in the solid

to that in the liquid. Often, this quantity is less than one,
signifying that solute will be rejected into the liquid at the
solid/liquid interface. When this quantity is greater than one,
the region just ahead of the solid/liquid front is depleted of
solute (below the base level). This parameter has no unit. This
information is needed to calculate the instantaneous stable
eutectic temperature as solidification proceeds. During
eutectic growth, the solute level will change in the liquid region
of a eutectic grain as solidification proceeds. Depending on the
amount of solute in the liquid, the eutectic temperature will
change. However, the metastable eutectic temperature is
assumed to be stationary at this point. The partition coefficient

MATERIALS
may be entered as a constant or as a function of temperature.

The temperature function should be used when the liquidus
slope in the binary phase diagram is not constant.
Constant: Enter the Partition Coefficient value in the input line.
Enter the temperatures in column one and Partition

SOLVENT MELTING POINT refers to the melting point of the solvent

element or of the pure metal. For example, if your material is a
Fe-4.3%C eutectic, you will enter the melting point of pure Fe
as the solvent melting point. Here iron is the solvent and
carbon is the solute.
STABLE GROWTH CONSTANT is the proportionality constant

describing the growth rate of eutectic cells which is proportional
to the square of the undercooling ahead of the solid/liquid
interface. A typical value for a Fe-Graphite eutectic in cast iron
is of the order of 7e-7 cm/sec/K2. This number will vary
depending on the material chosen. For a given material, this
number may be obtained from the appropriate growth
mechanism or from the literature.
Constant: Select the units from: {m/sec/K**2 | cm/sec/K**2 |
mm/sec/K**2 | ft/sec/F**2 | in/sec/F**2 | m/min/K**2 |
cm/min/K**2 | mm/min/K**2 | ft/min/F**2 | in/min/F**2}

MATERIALS
SUBSTRATE DENSITY is used to enter nucleation data. Substrate

density can be entered as a function of either the cooling rate or
temperature depending upon whether you chose the
Instantaneous or the Continuous Nucleation model. Based
upon that choice, PreCAST will display the correct input dialog
options when you select the SUBSTRATE DENSITY
parameter. If you chose Instantaneous, you will specify the
substrate density as a function of the cooling rate. If you chose
Continuous, you will specify the substrate density as a function
of temperature.
Allowing the substrate density to vary as a function of cooling

rate allows for a non-uniform distribution of grain sizes across a
casting. If you expect to have metastable eutectic formation,
one of the entries should contain the critical cooling rate with
the corresponding value of substrate density for the metastable
eutectic.
You may need to obtain this data from a carefully conducted

experiment. As long as the melt chemistry and process
parameters do not change very much, these data can be used
for different simulations.
For Instantaneous, specify:

Linear function: Select the Cooling Rate units from : {K/sec |
C/sec | F/sec | R/sec | K/min | C/min | F/min | R/min}
Select the Substrate Density units from: {1/m**3 |

1/cm**3 | 1/mm**3 | 1/ft**3 | 1/in**3}
Enter the Cooling Rate values in column one and

Substrate Density values in column two.
For Continuous, specify:

Linear function: Select the Temperature units from : {C | F | R |
K}

1/cm**3 | 1/mm**3 | 1/ft**3 | 1/in**3}
Enter the Temperature values in column one and


MATERIALS
TRANSFORMATION TEMPERATURE refers to the temperature at

which eutectic solidification begins to nucleate in the liquid.
This parameter can be a constant or a function of cooling rate.
With an increase in cooling rate, the transformation
temperature is expected to drop from the equilibrium value. In
the case of a stable to metastable transition, the critical cooling
rate value you chose needs to be one of the entries in the
transformation temperature vs. cooling rate table.
Constant: Select the Temperature from: {K | F | C | R}

Enter the Transformation Temperature in the Edit
Value line.
Select the Transformation Temperature units from: { K |

F | C | R}

Transformation Temperature values in column
two.
DUCTILE IRON EUTECTIC

The eutectic growth process in ductile iron is a divorced growth of
austenite and
graphite, which do
not grow
concomitantly. This
growth is simulated
beginning with an
instantaneous
nucleation model
and a growth model
that solves the
diffusion a carbon
from liquid through
the austenitic shell
into graphite nodule.

MATERIALS

which eutectic solidification begins. This parameter can be a
constant or a function of cooling rate. With an increase in
cooling rate, the transformation temperature is expected to drop
from the equilibrium value.

Value line.

F | C | R}

Transformation Temperature values in column two.
NODULE COUNT allows you to describe the nucleation data. The

nucleation law used is instantaneous in nature, meaning that all
the grains are nucleated at the same temperature. You may
choose to enter the nucleation data as a function of the cooling
rate. Normally, a high value of nodule count is associated with
a high value of cooling rate. However, if you wish to use a
constant value for the nodule count, you may enter two
identical values of the nodule count for a desired range of
cooling rates. Be careful about the unit of nodule count. The
number required here should be per unit volume.

Select the Nodule Count units from: {1/m**3 | 1/cm**3 |

1/mm**3 | 1/ft**3 | 1/in**3}

Nodule Count values in column two.

MATERIALS
DUCTILE IRON EUTECTOID

This model is used to simulate the solid state transformation in ductile
iron. It may be used during the eutectoid transformation while
describing the complete phase transformation of ductile iron from
pouring temperature to room temperature. It may also be used when
the iron is heated
from room
temperature to the
austenitizing
temperature and then
annealed or
normalized as part of
a heat treatment
procedure.
This model simulates

the decomposition of
austenite into ferrite
and graphite at the
stable eutectoid temperature and austenite to pearlite at the metastable
eutectoid temperature. These stable and metastable temperatures are
known from the literature. Usually this model should be used in
conjunction with the eutectic ductile iron model. However, if you are
just interested in modeling the solid state transformation starting from a
temperature less than the eutectic temperature, then you may use this
model alone.
TRANSFORMATION TEMPERATURE is used to enter the eutectoid

transformation temperature as a constant or as a function of
cooling rate. The maximum stable eutectoid temperature used
is 1063 (K. Therefore, your transformation temperature should
be 1063 (K and greater than the metastable eutectoid
temperature, which is taken as 1033 (K.

Value line.


F | C | R}


MATERIALS
NODULE COUNT allows you to describe the nucleation data. The

nucleation law used is instantaneous in nature, meaning that all
the grains are nucleated at the same temperature. You may
choose to enter the nucleation data as a function of the cooling
rate. Normally, a high value of nodule count is associated with
a high value of cooling rate. However, if you wish to use a
constant value for the nodule count, you may enter two
identical values of the nodule count for a desired range of
cooling rates. Be careful about the unit of nodule count. The
number required here should be per unit volume. If you have a
eutectic model for the liquid/solid transformation, then the same
nodule count values may be entered here.

Select the Nodule Count units from: {1/m**3 | 1/cm**3 |

1/mm**3 | 1/ft**3 | 1/in**3}

Nodule Count values in column two.
EQUIAXED DENDRITE
This model is based on instantaneous nucleation, whereby the final
grain size is known from the nucleation model.

MATERIALS
ALLOY COMPOSITION refers to the composition of the solute in

solvent in wt% units. For example, if your casting material is a binary
Al-7%Si alloy, then you would set the alloy composition to 7 (wt%). For
a multi component alloy system, one needs to use an approximate
pseudo-binary system and enter the weighted solute content. For
example, in case of cast iron the appropriate procedure will be to enter
the carbon equivalent value.
DIFFUSIVITY is used to describe the solute diffusivity in liquid. This

parameter may be a constant quantity or a function of
temperature. Generally, diffusivity is expected to change with
temperature as solidification proceeds.
Constant: Select the Diffusivity units from the following choices:

{m**2/sec | cm**2/sec | mm**2/sec | ft**2/sec | in**2/sec
| m**2/min | cm**2/min | mm**2/min | ft**2/min |
in**2/min}

input line.
Linear function: Select the Temperature units from: {K | C | F |

R}
Select the units from: {m**2/sec | cm**2/sec |
mm**2/sec | ft**2/sec | in**2/sec | m**2/min | cm**2/min
| mm**2/min | ft**2/min | in**2/min}
Enter the temperatures in column one and Diffusivity

GIBBS-THOMPSON coefficient is used for calculating the curvature

undercooling at the dendrite tip. A typical value for an Al-Si
alloy is 2.0 * 10-7 m*K. This is a material constant.
Constant: Select the units from: {m*K | cm*K | mm*K | ft*F |

in*F}

MATERIALS
LIQUIDUS SLOPE corresponds to the liquidus slope in a binary or a

pseudo-binary phase diagram. Please note that the slope is
expected to be a negative quantity and you may have to select
the appropriate side of the phase diagram. The liquidus slope
can be a constant quantity or a linear function of solute
composition. If you select the function of composition, make
sure that you enter solute concentration in wt %.
Constant: Select the Liquidus Slope units from the following
choices: {K/wt% | C/wt% | F/wt% | R/wt%}

input line.
Linear function: Select the Liquidus Slope units from: {K/wt% |

C/wt% | F/wt% | R/wt%}
Enter the Solute Concentrations in column one and

Liquidus Slope data values in column two.
PARTITION COEFFICIENT gives the ratio of solute solubility in the

solid to the liquid. Often, this quantity is less than one,
signifying that solute will be rejected ahead of the dendrite tip.
When this quantity is greater than one, the region just ahead of
the tip is depleted of solute (below the base level). This
parameter has no unit. This parameter may be given as a
constant or as a function of temperature. The temperature
function should be used when the liquidus slope in the binary
phase diagram is not constant.

Coefficient Data values in column two.

MATERIALS
SUBSTRATE DENSITY is used to enter nucleation data. The

nucleation law used is instantaneous. However, substrate
density is allowed to vary as a function of cooling rate. This
allows for a non-uniform distribution of grain sizes across a
casting.
You may need to obtain this data from a carefully conducted

experiment. As long as the melt chemistry and process
parameters do not change very much, these data can be used
for different simulations. A continuous nucleation law cannot
be used with this model.


1/cm**3 | 1/mm**3 | 1/ft**3 | 1/in**3}


which the equiaxed dendrites begin to nucleate in the liquid.
This parameter can be a constant or a function of cooling rate.
With an increase in cooling rate, the transformation
temperature is expected to drop from the equilibrium value.

Value line.

F | C | R}


MATERIALS
GRAY IRON EUTECTOID

The gray iron eutectoid transformation model is used to simulate the
solid state
transformation in
gray iron. Nucleation
and growth of ferrite
takes place once the
temperature drops
below the stable
eutectoid
transformation
temperature. If the
transformation of
austenite is not
complete when the
metastable eutectoid
temperature is reached, then nucleation and growth of pearlite takes
place.
This model simulates the decomposition of austenite into ferrite and

graphite at the stable eutectoid temperature and to pearlite at the
metastable eutectoid temperature. This model uses a statistical model
for the nucleation law. Also, it uses the values of growth constants of
different phases from the literature.

which eutectic solidification begins or the equiaxed dendrites
begin to nucleate in the liquid. This parameter can be a
from the equilibrium value.

Value line.

F | C | R}


MATERIALS
GRAY/WHITE IRON EUTECTIC

This model is a special case of coupled eutectic growth model and is
applicable to cast iron only. In cast iron, one may obtain both gray and
white iron depending
on the melt
composition and
cooling conditions.
Given a controlled
melt composition, the
most important factor
that will determine
whether a given
region will solidify as
white or gray is the
cooling rate.
This model differs

from the Coupled
Eutectic Growth Models in that the nucleation is described by a
statistical nucleation law.
The growth constant values for gray and white iron are obtained from
the literature. The COUPLED EUTECTIC GROWTH MODEL can also
be used for modeling the solidification of eutectic gray/white iron.
GRAY TO WHITE TRANSITION COOLING RATE--you are required to

enter the critical cooling rate for the gray to white transition.
This parameter should be determined from experiment.
Constant: Select the units from the following choices: {K/sec |


MATERIALS

which eutectic solidification begins. This parameter can be a
from the equilibrium value. Special care are must be taken in
the case of a stable to metastable transition. The critical
cooling rate value you chose needs to be one of the entries in
the transformation temperature vs. cooling rate table. The
critical cooling rate value should correspond to the appropriate
metastable eutectic temperature. The metastable eutectic
temperature is a constant quantity.

Value line.

F | C | R}


MATERIALS
PERITECTIC TRANSFORMATION
In a peritectic transformation, liquid reacts with an existing solid phase
to form a new solid phase. Once the new solid phase is formed, further
reaction between the parent phases is limited by the layer of solid
formed. Therefore the rate of reaction is controlled by the diffusion of
solute through this layer of the transformed product.

solvent in wt% units. For a multi component alloy system, one
needs to use an approximate pseudo-binary system and enter
the weighted solute content.
EUTECTIC COMPOSITION refers to the final composition that the

liquid reaches before the end of solidification. Normally,
solidification finishes with a terminal eutectic reaction. For
example, you would enter 4.3% as the eutectic composition
when the material you selected is cast iron.

MATERIALS
GIBBS-THOMPSON coefficient is used for calculating the curvature

undercooling at the dendrite tip. A typical value for an Al-Si
alloy is 2.0 * 10-7 mK.
Constant: Select the units from: {m*K | cm*K | mm*K | ft*F |

in*F}
LIQUID DIFFUSIVITY refers to the diffusion coefficient of the solute

element in the liquid phase. In the Fe-C system, this is the
diffusion coefficient of carbon or carbon equivalent in liquid.

in**2/min}

input line.
R}


MATERIALS
LIQUIDUS SLOPE corresponds to the liquidus line in a binary or a

expected to be a negative quantity. The liquidus slope can be
a constant quantity or a linear function of solute composition. If
you select the function of composition, make sure that you
enter solute concentration in wt %.
The figure shown here is a schematic representation of the Fe-

C peritectic region. The liquidus slope refers to the slope of the
line AD. The letter P refers to the peritectic point. In this
figure, the equilibrium amount of Reacting Fraction of Solid is
given as the ration of PD over ED.


input line.


MATERIALS
REACTING FRACTION OF SOLID refers to the amount of solid

fraction reacting with the liquid phase to produce the new solid
phase. In the peritectic reaction, it means the amount of the
primary phase that is reacting with liquid. Actually, this number
should be obtained with an equiaxed dendrite model for the
growth of the delta phase. However, for the time being, you will
have to enter here the equilibrium amount of the primary
phase.
SOLID FORMING PARTITION COEFFICIENT refers to the partition

coefficient of the solute element in the phase being formed and
the liquid phase. In the context of the Fe-C system, this
parameter refers to the partition coefficient of carbon or carbon
equivalent among the gamma and the liquid phase. This
coefficient can be constant or functions of temperature.

input line.

SOLID REACTING DIFFUSIVITY is the diffusion coefficient of the

solute element in the reacting solid phase. In the Fe-C system,
this is the diffusion coefficient of carbon in the delta phase.
This diffusivity parameter may be a constant or a function of
temperature.

in**2/min}

input line.
R}


MATERIALS
SOLID REACTING PARTITION COEFFICIENT refers to the partition

coefficient of the solute element among the reacting solid
phase and the liquid phase. For the Fe-C system, this means
the partition coefficient of carbon or carbon equivalent among
the delta and the liquid phase. This coefficient can be constant
or functions of temperature.

input line.

SOLID FORMING DIFFUSIVITY refers to the diffusion coefficient of the

solute element in the forming solid phase. In the Fe-C system,
this is the diffusion coefficient of carbon in the gamma phase.
The diffusivity parameter may be a constant or a function of
temperature.

in**2/min}

input line.
R}


MATERIALS

which peritectic reaction starts. This can be a constant quantity
or a function of temperature.

Value line.

F | C | R}

SCHEIL
The Scheil model makes the assumptions of complete mixing of solute
in liquid and no solute diffusion in the solid phase.

solvent in wt% units. For a multi component alloy system, one
needs to use an approximate pseudo-binary system and enter
the weighted solute content.

MATERIALS
FINAL TEMPERATURE usually corresponds to the eutectic

temperature or the temperature at which the solidification ends.
If the eutectic temperature value is entered here, then evolution
of fraction of solid by this model will stop and an eutectic
growth model, if chosen, will control the remaining solidification
process.

LIQUIDUS SLOPE corresponds to the liquidus line in a binary or a

expected to be a negative quantity. The liquidus slope can be
a constant quantity or a linear function of solute composition. If
you select the function of composition, make sure that you
enter solute concentration in wt %.


input line.

PARTITION COEFFICIENT gives the ratio of solute solubility in the

solid to the liquid. Often, this quantity is less than one,
signifying that solute will be rejected ahead of the dendrite tip.


Coefficient Data values in column two.

MATERIALS
SOLVENT MELTING POINT refers to the melting point of the solvent

element or of the pure metal. For example, if your material is a
Fe-4.3%C eutectic, you will enter the melting point of pure Fe.
Here iron is the solvent and carbon is the solute.
Constant: Select the units from the following choices: {K | F | C

| R}

which the solidification begins. This parameter can be a
constant or a function of cooling rate.

Value line.

F | C | R}

SOLID TRANSFORMATIONS
This model is only applicable to the Fe-C system and is used for
tracking the fraction
transformed for the
cases of delta to
gamma, gamma to
ferrite, and gamma to
cementite. If the wt%
of carbon equivalent
is less than or equal
to 0.17%, the delta to
gamma
transformation will be
activated in the
appropriate
temperature range.
The value of this carbon equivalent will control whether gamma to
ferrite or gamma to cementite will take place during subsequent the
proeutectoid transformation.
WT% CARBON EQUIV

MATERIALS
ASSIGN is a push
button in the MICRO
sub-menu. It provides
the capability to
associate properties
from the database
with material IDs in
the model.
ASSIGN is activated
by clicking on it. This
results in the
immediate action to
display a table
containing a list of the
material regions
which have been
defined in the model.
It also displays a table
of the material micro
models in the
database. The figure
shown here illustrates
a display for a model
with two Material
Regions and the
Micro Database
entries.
When you select an entry from this table by clicking on the ID# or the
Material Name, the elements in the model with a corresponding ID
number will be redrawn in the work window pane in a color unique to
the respective table entry.

MATERIALS
To assign a micro model to a region of the model:

1. Select the region by clicking the desired table entry.
2. Select a material from the database by moving the cursor down to
the window displaying the MICRO DATABASE entries. If the
model you want is not visible in the table at first, you may scroll
to the desired entry.
3. When you have located the desired micro model entry, click on it.
button. This will place the database entry number in column
three of the Assignment Table.
To associate micro models with other regions, repeat steps one through
four.
You may examine and/or modify the properties for Micro Database
entries by clicking the READ/MODIFY push button in the Micro
Database display window.
button in the Assignment Table. This will store the assignments and
close the display. You may close this display without storing any
assignments by clicking the CANCEL push button.
Remarks The ultimate aim of micromodeling is to predict the microstructure of

castings. The mechanical properties of the castings can then be
predicted from a knowledge of the microstructure.
Micromodels can not accomplish this task alone however. They have
to be incorporated into macromodels to achieve this goal. Coupling the
macro- and micromodels is accomplished through the source term in
the energy equation. The rate of evolution of the fraction of solid is
calculated by the micromodels, which controls the release of latent
heat.
A combination of different micromodels can be chosen in a single

simulation run by adding the appropriate MICRO parameters
corresponding to individual micromodels. This is done automatically in
PreCAST when different micromodels are assigned to the different
materials in the model. PreCAST allows you to assign the desired
micromodels to the particular material.
The rest of this section will discuss specific issues related to individual
micro models. For convenience of presentation, these will be
presented alphabetically.

MATERIALS
COUPLED EUTECTIC--should be selected when the material chosen

will solidify at some stage in a eutectic mode. The eutectic
could be a stable or metastable. Both the regular and the
irregular eutectic solidification are described with this model.
The growth of either stable or metastable eutectic may proceed
following either an instantaneous or continuous nucleation law.
In the case of regular eutectics, growth of both phases of the
eutectic structure are non-faceted in nature. For irregular
eutectic, the growth process of one of the phases is faceted.
Growth of the faceting phase requires considerably higher
entropy of fusion. Examples of faceted growth are graphite
growth in stable austenite/graphite eutectic and Silicon in Al-Si
eutectic. The metastable austenite/ cementite eutectic is an
example of non-faceted/non-faceted type eutectic growth.
Growth of both the stable and metastable eutectic are

addressed here. Growth of the stable eutectic usually proceeds
at a higher temperature. For example, the difference between
the stable and metastable eutectic temperature in cast iron is
about 6 (C. This value may, however, be influenced by the
amount of alloying elements present. A higher cooling rate
results in the formation of a metastable eutectic.
All of the nucleation and growth types of micromodels

discussed here assume bulk heterogeneous nucleation at
foreign sites which are already present within the melt or
intentionally added to the melt by inoculation. So these models
are valid for the equiaxed region of castings.
The instantaneous nucleation model is modified to take into

account the dependance of cooling rate on the number of
nucleation sites or substrates. With an increase in cooling rate
or undercooling, the number of substrates increases which
explains the existence of more grains in faster cooled regions
of a casting.
In continuous nucleation, the process starts at the nucleation

temperature and proceeds until the stage when the minimum in
the cooling curve is attained.
Regardless of the nucleation process, the models assume that

the grains are equiaxed and that they grow freely in liquid as
spheres until they impinge on each other. The micromodels
use a correction factor for impingement of grains. The growth
process stops when all the liquid is consumed.

MATERIALS
DUCTILE IRON EUTECTIC--At the beginning of the liquid/solid

transformation, graphite nodules nucleate in the liquid and grow
in the liquid to a small extent. The formation of graphite
nodules and their limited growth in liquid depletes the melt
locally of carbon in the vicinity of the nodules. This facilitates
the nucleation of austenite around the nodules, forming a shell.
Further growth of these nodules is possible by diffusion of
carbon from the melt through the austenite shell to the graphite
nodule.
ProCAST simulates this growth beginning with an

instantaneous nucleation model that determines the final grain
size from the local cooling rate at the onset of solidification.
Once the austenite shell is formed around each nodule, the
diffusion equation for carbon through the austenitic shell is
solved. Boundary conditions are known from the phase
diagram because thermodynamic equilibrium is maintained
locally. Conservation of mass and solute is maintained in each
grain. Because of the density variation resulting from the
growth of austenite and graphite, the expansion/contraction of
the grain is taken into account by allowing the final grain size to
vary. Toward the end of solidification, the grains impinge on
each other.
DUCTILE IRON EUTECTOID--The eutectoid reaction leads to the

decomposition of austenite into ferrite and graphite for the case
of the stable eutectoid and to pearlite for the metastable
eutectoid transformation. Usually, the metastable eutectoid
temperature is lower than the stable eutectoid temperature.
Slower cooling rates result in more stable eutectoid structure.
EQUIAXED DENDRITE--This model should be used to simulate the

primary phase solidification of an off-eutectic alloy.
GRAY IRON EUTECTOID--The gray iron eutectoid transformation

model is based on the approach used for gray iron eutectic and
a statistical distribution is assumed. In this statistical approach,
nucleation and growth takes place once the temperature drops
below the transformation temperature. When nucleation ends
at the minimum point of the cooling curve, the existing nuclei
continue growing until the transformed fraction becomes 1.
The number of nuclei does not change from this point on.

MATERIALS
GRAY/WHITE IRON EUTECTIC--This model is a special case of

coupled eutectic growth model and is applicable to cast iron
only. If a region of a casting solidifies with a cooling rate higher
than the critical cooling rate, then it will be white. The reverse
is the case for gray iron. The white structure is brittle and in
most gray iron castings, it is considered to be deleterious. This
model describes nucleation by a continuous distribution
function.
PERITECTIC TRANSFORMATION--In conventional models, a new

solid is assumed to form at the interface between the parent
liquid and solid phases in a peritectic transformation when the
liquid reacts with an existing solid phase. Once the new solid
phase is formed, the rate of reaction is controlled by the
diffusion of solute through the shell of the transformed product.
Some researchers have suggested that the peritectic
transformation may be achieved through a liquid layer between
the parent and the product solid phases. This mechanism has
been adopted in the present model.
More detailed discussion about these properties, models, data, and

their use may be found in the Mathematical Formulations Appendix.

DATABASE, MATHEMATICAL FORMULATIONS

MATERIALS
MATERIALS
INVERSE
Description INVERSE is a push button in the MATERIALS menu which allows you
to select the materials in the model for which the thermophysical
properties will be calculated using the inverse calculation method.
These calculations will be based upon the geometry, initial conditions,
boundary conditions, and thermal history.
Method INVERSE is activated by

clicking on it. This results in
the immediate action to
display a table displaying a
list of the materials in the
model. The figure shown
here illustrates this display.
As shown in this figure, there

are three columns on the
right side of the table. The
headings are: CpSpecific
heat per unit mass, K--Thermal conductivity, and L--Latent heat.
Beneath these headings are rows of toggle switches. There is one row
of switches for each material in the table. You specify the material
properties for each material which are to be calculated using the
inverse calculation method by toggling the corresponding switch to the
Y or yes position.
Successive clicks on these switches will toggle between Y and N or no.
Remarks If you do Materials--Inverse, you cannot concurrently do either the

interface or boundary condition determinations using the inverse
method.
Related Topics MATERIALS

INTERFACE
INTERFACE
Description INTERFACE is a push button in the Main Function Banner. This

function of PreCAST enables you to describe the thermal interfaces
between dissimilar material IDs. It also enables you to add, modify and
delete interfacial heat transfer coefficient information in the database
and assign these specific interface descriptions to elements in the
model. When you activate the INTERFACE push button, a menu is
opened which will allow you to choose the interface operation you wish
to perform. Selections from the menu provide capabilities which will be
discussed in this section.
Method INTERFACE is activated by clicking on it. The initial menu is shown

this menu, PreCAST will display
the interfaces in the database.
You may leave the INTERFACE function by clicking another push

button in the Main Function Banner.
Remarks ProCAST provides the capability and flexibility to add, delete, or modify
an interface in the interface database. Once Interface data is in the
database, you can proceed to the ASSIGN function to associate these
interface definitions with specific elements in the model.
The major capabilities of the INTERFACE function of PreCAST will be

this manual.
DATABASE
Provides the data management functions for the interface
descriptions and their respective properties in your database.
DATABASE allows you to add, delete, copy, and modify entries
in the interface database.
CREATE
Provides the capability to create coincident nodes between
pairs of adjacent materials.

INTERFACE
ASSIGN
Provides the capability to associate interface properties with
elements in the model.
MULTI-POINTS
Provides the capability for you to glue together element
regions when the nodes do not align. Multi-points can only be
used in a thermal solution or in the mold of a fluids analysis.
INVERSE
Provides the capability to configure the problem to use the
inverse calculation method for the determination of interface
heat transfer coefficients.

interface database.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE, INTERFACE--

DATABASE, INTERFACE--CREATE, DATABASE--ASSIGN,
DATABASE--MULTI-POINTS, DATABASE--INVERSE

INTERFACE
INTERFACE
DATABASE
Description DATABASE is a push button in the INTERFACE menu which accesses

the Interface Database. Using ProCASTs DATABASE FACILITY you
may create, delete, or modify an interface or its properties in the
interface database. These interface descriptions may then be used for
simulation and analysis.

action to display a table containing any interface descriptions which
may be in the database. The figure shown here illustrates a display of
the materials in the
Interface Database.
PreCAST allows you

to Read, Add, Copy,
and Delete interface
descriptions from the
Interface Database.
These capabilities
are described in the
DATABASE
FACILITY section of
this manual. You
the TABLE
MAINTENANCE
section of this
manual which
describes ProCASTs graphical interface for maintaining tables.
This section will discuss the requirements for adding an interface

description to the database and how you specify individual properties
and attributes for that interface.
To add an interface description to the database, click on the ADD push

button in the Interface Database display. This will result in the
immediate action to open a blank Interface Description and an option
sub-menu which are shown below. Note that PreCAST has entered the
USER name and the DATE for you.

INTERFACE
The minimum requirement for adding an interface description to the

database is to give it a KEY or name and define a heat transfer
coefficient.
The syntax and options available for the Interface Description are
discussed below.
KEY:
Enter the name you want to give the new interface description. Since
you are describing a coefficient for an activity between two materials, it
may be helpful to enter a key which will be easy for you to remember.
For example, you could enter Al, Fe to identify an interface between
Aluminum and Iron or My_Al_SpecialOne, My_Sand for an interface
between alloys and materials which you have compounded. The key
word must begin with an alphabetic character and may include upper
and lower case characters.

INTERFACE
HEAT TRANSFER COEFFICIENT:

PreCAST provides three ways for you to specify the Heat Transfer
Coefficient for an interface. It may be a constant quantity or a function
of time and/or temperature. As shown in the option sub-menu in the
figure above, these options are: CONSTANT, TIME, or
TEMPERATURE, respectively. To select a method, click the left
mouse button when the cursor is over the corresponding push button.
This will result in the immediate action to display an additional dialog
box or data input table.
Selecting CONSTANT will open an input box as shown here. Notice

that it has a rotary toggle switch for the units of measure and a text
input line. Select the
desired units of
measure by clicking
on the UNITS push
button. Successive
clicks on this push
button will toggle
through the available options.
Select the Interface Coefficient units from the following choices:

{W/m**2/K | cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**/F/sec |
Btu/in**2/F/sec | cal/cm**2/C/min | Btu**2Fmin | Btu/in**2/F/min}
To enter the desired constant value to be used, move the cursor to the
text input line and type the value. When you click on the APPLY push
button, the data entered will be stored, the dialog box will be closed,
and the CONSTANT push button on the Interface Description display
will be highlighted in light blue.

INTERFACE
Selecting the TIME or

TEMPERATURE
option will result in
the immediate action
to display the
appropriate input
table. These tables,
like the dialog box for Rotary Toggle Switch
a constant, will
of measure. As
shown in this
example for TIME,
there is a toggle
switch which also
serves as the column
sub-heading for the
table.
The TIME option allows you to enter the interfacial heat transfer
coefficient as a linear function of time.

push button. Successive clicks on these push buttons will toggle
through the available options. To enter a table value, select the first or
next available table entry, move the cursor to the text input line, type
the value, and press the ENTER key. This will place the value in the
table and move the cursor to the next available table entry.
Select the time units from the following choices: {sec | min}

INTERFACE
When you are satisfied with the table entries, click on the STORE push
button, the data in the table will be stored, the dialog box will be closed,
and the TIME push
button on the
Interface Description
display will be
highlighted in light
blue.
The TEMPERATURE
option allows you to
enter the interfacial
heat transfer
coefficient as a linear
function of
temperature. The
input display shown
here will be displayed
when you select the
TEMPERATURE
option.
Select the Temperature units from the following choices: {K | C | F | R}
Select the Interface Coefficient units from the following choices:

{W/m**2/K | cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**/F/sec
| Btu/in**2/F/sec | cal/cm**2/C/min | Btu**2/F/min |
Btu/in**2/F/min}
Enter the temperatures in column one and Interface Coefficient values

in column two.
When you are satisfied with the table entries, click on the STORE push
button, the data in the table will be stored, the dialog box will be closed,
and the TEMPERATURE push button on the Interface Description
display will be highlighted in light blue.
For either the TIME or TEMPERATURE options, you may click on the
GRAPH push button to display a graph of the function. You may click
on the ERASE push button to erase the entire contents of the table.

INTERFACE
COMMENTS: This portion of the Interface Description is a free format

text box which may be used to annotate the interface
coefficient. For example, you may want to describe the
sources for the data entered or techniques used to develop the
data.
Remarks Interfacial heat transfer coefficient information depends on the

materials involved, the geometry, coating properties and thickness, and
on the relative deformation of the part and mold. Normally, this data is
acquired by experiment, although some ballpark numbers are available
in the literature.
You may apply the Interface Transfer Coefficient by using combinations

of the CONSTANT, TIME, and TEMPERATURE definitions. You can
have the following combinations:
1. CONSTANT,
2. CONSTANT + TIME,
3. TEMPERATURE,
4. TEMPERATURE + TIME, or
5. TIME.
If you complete and save a TEMPERATURE linear function table, the

constant value will be set to 1.0. If you apply a constant value, even if
it is 1.0, the Temperature Table is abandoned.

INTERFACE
INTERFACE
CREATE
Description CREATE is a push button in the INTERFACE menu which allows you to
create interfaces between selected pairs of adjacent materials. Using
this capability you may create coincident nodes between these adjacent
materials. Once created, these interface elements may then be
associated with interface descriptions for use in simulation and analysis.
Method CREATE is activated by clicking on it. This results in the immediate

action to display a table listing the material combinations which share
nodes in the geometry is also displayed. The figure shown here
illustrates a geometry and a display which contains two pairs of
adjacent materials.
Material 1
Interface
Material 2
Material 3
Creating interface nodes is a three step process.

1. Select a material pair for which you want the interface nodes
created. When you click on a material pair, the
elements with those material IDs will be drawn in blue
and red in the work window pane. The interface will be
highlighted in green. The insert to the figure above
illustrates these three items in the work window pane.
2. Set the YES--NO toggle switch for the selected pair to YES.
Each row in the Adjacent Materials table represents a
material pair. In the right-most column of each entry is
a YES--NO toggle switch. Successive clicks on this
switch will toggle between YES and NO.

INTERFACE
3. Repeat steps One and Two until all of the desired material
pairs have been set to YES. It is not necessary to set
the switch to YES for every pair shown. However, you
must set the switch to YES for those pairs which should
have interface nodes before clicking the EXECUTE
push button.
4. Click on the EXECUTE push button in the Adjacent

Materials display table. EXECUTE will create the new
coincident nodes. These nodes will be displayed as red
dots in the work window pane. These new nodes are
shown in the example below.
Coincident Nodes
Click on the QUIT push button to close the dialog box.
Remarks The EXECUTE function can only be activated once, not separately for
each pair. Execute generates an extra set of nodes at the interface and
automatically reorganizes the element connectivities. Once the
interface nodes have been created, you can not go back and rearrange
your interface selections. The only way to change these interface
selections is to start over with a new copy of the initial geometry.
Filters do not need interfaces between the fluid and filter. If you create
such an interface, the fluid will not flow through the filter.
Related Topics TABLE MAINTENANCE

INTERFACE
INTERFACE
ASSIGN
Description ASSIGN is a push button in the INTERFACE menu. It provides the

capability to associate heat transfer coefficients from the database with
element IDs in the model.
Method ASSIGN is activated by clicking on it. This results in the immediate

action to display a table containing a list of the material pairs between
which exist interface nodes. The first column of this list will contain
either a C to indicate
that the nodes in this
pair are Coincident or
an N to indicate that
they are Non-
coincident.
A table of the heat

transfer coefficients
in the Interface
Database is also
displayed. The figure
shown here illustrates
a display for a model
which contains one
pair of materials with
interface nodes.
As you click on one

of the material IDs in
the pair, the two
materials are drawn
in blue and red in the
work window pane.

INTERFACE
To assign an interface coefficient:

1. Select an entry from the Material Pairs DB list by clicking on the
desired table entry. The selected entry will be highlighted in
red.
2. Select an interface from the database by moving the cursor down to
the window displaying the INTERFACE DATABASE entries. If
the interface you want is not visible in the table at first, you may
3. When you have located the desired interface entry, click on it.
4. ASSIGN the interface to the material pair by clicking the ASSIGN
push button. This will place the interface database sequence
number in the DB ENTRY column of the MATERIAL PAIRS DB
display. In the figure above, notice that the number 5" has
been placed in this column because it corresponds to the
selected interface database table entry Clay, Sand.
To associate interface coefficients with other material pairs, repeat

steps one through four.
ADD is used for creating

interfaces between non-
aligning meshes. As shown
in the figure here, the nodes
in Material 7 and Material 6
do not align. Therefore,
when you click on the ADD
push button, an input dialog
box will open. In this dialog
box, you specify the two
material numbers for which you want to add and assign an interface.
The ADD capability is also used to define the interface between a fluid
and a filter.
DELETE is used to delete any unwanted interfaces.
button in the Material Pairs DB table display or click on a push button in
the Main Function Banner. This will store the assignments and close
the display.
Remarks The order of the material IDs in each row of the Material Pairs display
table is significant. If the interface coefficient to be assigned is a
function of temperature, PreCAST will use the surface temperature of
the first material ID in the row.
You may flip the sequence of the material IDs by clicking on the second
ID. Doing so changes the position of the material IDs, however it does
not change the materials or the interface. In the figure shown above,

INTERFACE
clicking on the number 3" would move it to the column which now
contains a 2" and the 2" would be moved to the column which now
contains the 3. The column which was clicked last remains
highlighted in red.
If you delete an interface, the mesh will not be changed. However,

there will not be any interface coefficient assigned.
If you intended the interface to be non-coincident and it happens to

align, you must delete the interface and re-add it to the model.
You may examine and/or

modify the interface
coefficients in the Interface
Database entries by clicking
the READ/MODIFY push
button in the Interface
Database display window.
This will display the Interface
Description Display as shown
here.
Related Topics DATABASE FACILITY,

TABLE MAINTENANCE,
INTERFACE--CREATE

INTERFACE
INTERFACE
MULTI-POINTS
Description MULTI-POINTS is a push button in the INTERFACE menu which allows

you to describe thermal constraints between element regions when
nodes do not align. The temperatures of the nodes on one side of a
multi-point interface are forced to be a linear combination of the nodal
temperatures on the other side of the interface. Using this capability
you specify tolerances which are used in the search for constraining
nodes. Once identified, the weighting factors are computed
automatically from the geometry by PreCAST.
Multi-points can only be used in a thermal solution or in the mold of

fluids analysis. This is because pressure gradients are not well
behaved across a multi-point interface.
Method MULTI-POINTS is activated by clicking on it. This results in the

immediate action to display a table listing the possible combinations of
materials between which multi-point constraints could be created.
In the Material Combinations display, M and S stand for master and

slave IDs. The slave nodes will be constrained by the master nodes.
Generally, you would want the coarser mesh to be the master side.
You may flip the material IDs, thereby changing the designation of the
master side, by clicking on the ID you want to be the master side.
Doing so changes the position of the material IDs, however it does not
change the materials or the interface. In the figure shown above,
clicking on the number 1", in row one column two, would move it to the
column which now contains a 2" and the 2" would be moved to the
column which now contains the 1. Accordingly, in this example,
material 1" would now be designated as the master side.

INTERFACE
Creating multi-point interface constraints is a five step process.

1. Identify a material pair for which you want the interface
constraint created. If you click on a material ID in the
Master column, the elements with those IDs will be
drawn in red in the work window pane.
2. Set the YES--NO toggle switch for the selected pair to YES.
Each row in the Material Combinations table represents
a material pair. The third column of each entry is a
YES--NO toggle switch. Successive clicks on this
switch will toggle between YES and NO.
3. Set the PLANE and PERIMETER tolerances to be used in
the search for constraining nodes.
4. Repeat steps One through Three until all of the desired
material pairs have been set to YES. It is not
necessary to set the switch to YES for every pair
shown.
5. Click on the EXECUTE push button in the Material
Combinations display table. EXECUTE will calculate
the weighting factors. The master nodes will be
displayed in red and the slave nodes will be displayed
in green in the work window pane.
To change the PLANE and/or PERIMETER tolerance, select the

desired table value by clicking the left mouse button when the cursor is
over the tolerance in the table. This will cause the value to be
highlighted in red. Move the cursor to the Edit Value line. Type the
new tolerance and press ENTER. This will place the new value in the
table entry.
Click on the QUIT push button to close the dialog box.
Remarks A multi-point interface is not like a thermal break interface because no

heat transfer coefficient is involved. You must assign a different
material ID to the elements on either side of the interface, even if they
will be assigned the same material properties.
A multi-point and a coincident node interface cannot be created

between the same material ID pair. Therefore, any material ID pairs
which were selected for coincident node interfaces will not appear in the
Material Combinations table display.

INTERFACE
PLANE and PERIMETER give tolerances which are used in the search
for constraining nodes. PLANE is a tolerance normal to the plane of the
interface. PERIMETER is the distance outside the edge of an element
face that a slave node can be and still be constrained by the nodes in
that face. This is illustrated in the figure shown here.
In-the-Plane Tolerance Node
Perimeter Tolerance
Element Face
Node
Related Topics INTERFACE--CREATE, TABLE MAINTENANCE

INTERFACE
Example As an example of the use of the multi-point constraints, the following

two figures are sketches of the finite element mesh above (shown on
the right) and below the multi-point constraint interface plane (shown on
the left).
Bottom Element Layout Top Element Layout
Y Y
Metal Mold
X X
The mesh has been created such that the metal elements will be
contiguous through the intersection. Therefore, no multi-point
constraints need be generated for the metal. The mold elements on
either side of the plane will have to be linked by multi-point constraints.
Normal to the multi-point interface plane there will be a coincident node
interface between the metal and the mold. Some care needs to be
taken while performing nodal equivalencing so that the metal nodes are
combined but the mold nodes are not.

INTERFACE
INTERFACE
INVERSE
Description INVERSE is a push button in the INTERFACE menu which allows you
to select the interfaces in the model for which the heat transfer
coefficients will be calculated using the inverse calculation method.
Method INVERSE is activated by clicking on it.

This results in the immediate action to
display a table listing the coincident and
non-coincident interfaces. The figure
shown here illustrates this display.
As shown in this figure, the column on the

right side of the table has the heading
indicating the heat transfer coefficient--H.
Beneath this heading is a toggle switch.
There is one switch in each row of the
table and corresponds to each set of
defined interfaces in the database. You specify the interfaces which
are to be calculated using the inverse method by toggling the
corresponding switch to the Y or yes position.
Remarks Using the inverse method for calculating an interface heat transfer
coefficient may be used in conjunction with Boundary Condition--
Inverse. However, it can not be used in conjunction with Materials--
Inverse.
The initial guess for the calculated interface coefficient is taken as the
database value that has been assigned.
Related Topics INTERFACE

BOUNDARY CONDITIONS
BOUNDARY
Description BOUNDARY is a push button in the Main Function Banner. This

function of PreCAST enables you to describe boundary conditions and
their properties in the database. It also enables you to assign boundary
conditions to element faces, nodes, and material IDs in the model.
When you activate the BOUNDARY CONDITIONS push button, a
menu is opened which allows you to work with the various capabilities
associated with Boundary Conditions. Selections from the menu
provide access to these capabilities and will be discussed in this
section.
Method BOUNDARY is activated by clicking on it. The initial menu is shown

the boundary conditions in the database.
These may be used in your model and
the analysis to be performed.
You may leave the BOUNDARY CONDITIONS function by clicking

another push button in the Main Function Banner.
Remarks The major capabilities of the BOUNDARY CONDITIONS function of

PreCAST will be summarized here. Each capability will be described in
greater detail in this manual.
DATABASE
Provides the data management functions for the boundary
conditions and their respective properties or attributes in your
database. DATABASE allows you to add, delete, copy, and
modify entries in the boundary condition database.
ASSIGN SURFACE
Provides the capability to select element faces or nodes,
combine them into sets, and assign boundary conditions to
each set.
ASSIGN VOLUME
Provides the capability to assign heat, momentum, mass, or
current density to particular material regions.

BOUNDARY CONDITIONS
PERMEABILITY
Provides the capability to account for the trapped gas which
escapes through the mold. This is intended primarily for sand
or shell molds.
INVERSE
Provides the capability to configure the problem to use the
inverse calculation method for the determination of HEAT
boundary conditions: film coefficient, heat flux, or emissivity.
When you select from the BOUNDARY CONDITIONS menu, additional

sub-menus, input displays, and dialog boxes will be displayed
depending upon the function you have selected.

materials database.
Each of the Boundary Condition menu choices will be described in this

section.
Related Topics DATABASE FACILITY

BOUNDARY CONDITIONS
BOUNDARY
DATABASE
Description DATABASE is a push button in the BOUNDARY menu which accesses

the Boundary Condition Database. Using ProCASTs DATABASE
FACILITY you may create, delete, or modify a boundary condition or its
properties in the boundary conditions database. These boundary
condition descriptions may then be used for simulation and analysis.

action to display a table containing any boundary conditions which may
be in the database. The figure shown here illustrates such a display.
PreCAST allows you

to Read, Add, Copy,
and Delete boundary
conditions from the
Boundary Condition
Database. These
capabilities are
described in the
DATABASE
FACILITY section of
this manual. You
the TABLE
MAINTENANCE
section of this
manual which
describes ProCASTs
graphical interface
for maintaining
tables.
This section will discuss the requirements for adding a boundary

condition to the database and how you specify individual properties and
attributes for that condition.
To add a boundary condition to the database, click on the ADD push

button in the Boundary Condition Database display. This will result in
the immediate action to open a sub-menu which lists the types of
conditions which may be described. This sub-menu is shown below.

BOUNDARY CONDITIONS
The characteristics, properties,

and options which are available
or required vary from one
Boundary Condition to another.
When you choose from this

menu, ProCAST will display the
appropriate input form and
options in a blank Boundary
Condition Description which is
shown below. For convenience
of illustration, the example shown
is the result of selecting the
CURRENT DENSITY option from
the sub-menu.
PreCAST also displays an option

box above the Boundary
Condition Description display.
The content of the option box
depends upon the type of
boundary condition you selected.
The option box may contain
properties or options which are
displayed as a group of check
boxes, push buttons, text input
lines, or a combination of these. In this case, the current density may
be designated as a CONSTANT or as a linear function of TIME.
Therefore, there are corresponding push buttons in the option box.
If the option box includes a

text input line, enter data in
a text input line by placing
the cursor in the text box,
typing the desired data,
and pressing ENTER. In
some cases, the text input
line will be accompanied
by a rotary toggle switch.
These toggle switches
allow you to choose the
desired value from a list of
options. Successive clicks
on the toggle switch will
cycle through the available
options.

BOUNDARY CONDITIONS

minimum requirement for adding a boundary condition to the database
is to give it a keyword name. All of the boundary condition descriptions
have two input text lines in common: KEYWORD and COMMENTS.
these descriptions, the individual options for each available boundary
condition are discussed.
KEYWORD: Enter the name you want to give the boundary condition
database entry. The boundary condition keyword must begin
with an alphabetic character and may include upper and lower
case characters.
COMMENTS: This portion of the Boundary Condition Description is a

free format text box which may be used to annotate the
boundary condition. For example, you may want to describe
the sources for any property data or techniques used to develop
the boundary condition or its properties.
To specify a property which is displayed in a check box, click on the

desired propertys check box. This will result in the immediate action to
display an additional option menu or
a input dialog box. Some properties
may be specified either as constants
or as a linear function. An option
menu, similar to the one shown here, will allow you to select the
property as either a CONSTANT or as a function of TIME, PRESSURE,
FLOW RATE, or TEMPERATURE.
ProCAST dynamically displays the appropriate property names, option

boxes, and input text lines based upon the type of boundary condition
option you select.
contain a rotary
units of measure.
toggle through the

BOUNDARY CONDITIONS
When you click on the APPLY push button or press ENTER, the data
entered will be stored, and the dialog box will be closed.
You may click on the

CANCEL push button
to close the dialog
box without saving
the data.
Selecting other
options usually
results in the
immediate action to
display an input
table. This table, like
the dialog box for a
constant, may
of measure. As
shown in this
example for Surface
Load, there are two
toggle switches which also serve as the column sub-headings for the
table.

table and move the cursor to the next available table entry. When you
are satisfied with the table entries, click on the STORE push button, the
data in the table will be stored, and the dialog box will be closed.
The method, syntax, and options for each Boundary Condition will be
presented below. For convenience of presentation, they are presented
in alphabetical order.

BOUNDARY CONDITIONS
CURRENT DENSITY
is used to define the current density flowing through an induction coil.
You may enter the
current density as a
constant or as a
function of time. The
time function
modifies the constant
value specified.
Accordingly, if you
use the TIME option,
the constant value
you provide will be
used. The default
constant value is 1.0.
Negative values of
current density will
reverse the current
flow.
For a 2D
electromagnetics problem, a positive value of current density is
assumed to flow out of the plane of the model towards the viewer. For
a 3D problem, a positive value of current density is assumed to flow in
the t or last parametric direction of an element. This type of definition,
restricts the construction of the induction coils. These coils must be
composed of either hex or wedge elements only. Tetrahedron elements
can not be used. Negative values of current density will reverse the
current flow.
Constant: Select the Current Density units from the following:

{amps/m**2 | amps/cm**2 | amps/mm**2 | amps/ft**2 |
amps/in**2}

Function of time: Select the time units from: {sec | min}
Select the Current Density units from the following:
{amps/m**2 | amps/cm**2 | amps/mm**2 | amps/ft**2 |
amps/in**2}
Enter the time values in column one and current

density values in column two.

BOUNDARY CONDITIONS
DISPLACEMENT
Is used to define the x, y, z displacement constraints for a stress
problem. You may
enter the
displacement as a
constant or as a
time function
modifies the constant
value specified.
Accordingly, if you
use the TIME option,
the constant value
you provide will be
used. The default
time value constant
is 1.0.
The default
DISPLACEMENT
setting is No
Constraint because
you may wish to
constrain only one
direction.
Displacement can be constrained in any or all coordinate directions.

The units selected will be applied to all constraint coordinate directions.
Constant: Select the Displacement units from the following: {m |

cm | mm | ft | in}
Enter the constant value to be used in each of the

appropriate (X:, Y:, and Z:) input lines.

Select the Displacement units from the following: {m |
cm | mm | ft | in}
Enter the time values in column one and displacement


BOUNDARY CONDITIONS
HEAT
Is used to define heat flux boundary conditions applied to element
faces. These
conditions may be a
combination of
prescribed heat flux,
convection, and
radiation. This is
known, by some, as
the Cauchy condition.
When you select

either the FLUX or
the AMBIENT TEMP
check box, you will
presented with an
additional option
menu from which you
may choose to enter
values for these characteristics as a constant or as a function of time.
When you select either the FILM COEFF or the EMISSIVITY check
box, you will be presented with an additional option menu from which
you may choose to enter values for these characteristics as a constant,
a function of time, and/or a function of temperature.
AMBIENT TEMP--indicates the temperature of the environment

surrounding the model and is used to calculate the convective
and/or radiation heat transfer. See Equations C.8.10 and
C.8.11 in Appendix C.
Constant: Select the Temperature units from the following: {C |
F | R | K}

Select the Temperature units from the following: {C | F |
R | K}
Enter the time values in column one and temperature


BOUNDARY CONDITIONS
EMISSIVITY--indicates the radiation of heat and is used to calculate

radiative heat transfer. See Equation C.8.11 in Appendix C.
This value should be between 0 and 1.
Enter the time values in column one and emissivity

Function of temperature: Select the Temperature units from
the following: {C | F | R | K}
Enter the temperature values in column one and

emissivity values in column two.
FILM COEFFICIENT--indicates the value of heat transfer and is used to

calculate convective heat transfer. See Equation C.8.10 in Appendix C.
Constant: Select the film units from: {W/m**2/K |
cal/cm**2/C/sec | cal/mm**2/C/sec | Btu/ft**2/F/sec |
Btu/in**2/F/sec | cal/cm**2/C/min | Btu/ft**2/F/min |
Btu/in**2/F/min}

Select the film coefficient units from: {W/m**2/K |
Btu/in**2/F/min}
Enter the time values in column one and film

coefficient values in column two.
Function of temperature: Select the Temperature units from
the following: {C | F | R | K}
Select the film coefficient units from: {W/m**2/K |
Btu/in**2/F/min}
Enter the temperature values in column one and film

coefficient values in column two.

BOUNDARY CONDITIONS
FLUX--indicates heat transfer in or out of the model. See Equation

C.8.9 in Appendix C.
Constant: Select the flux units from: {W/m**2/sec |
cal/cm**2/sec | cal/mm**2/sec | Btu/ft**2/sec |
Btu/in**2/sec | cal/cm**2/min | Btu/ft**2/min |
Btu/in**2/min}

Select the flux units from: {W/m**2/sec | cal/cm**2/sec
| cal/mm**2/sec | Btu/ft**2/sec | Btu/in**2/sec |
cal/cm**2/min | Btu/ft**2/min | Btu/in**2/min}
Enter the time values in column one and flux values in

column two.
VIEW FACTOR--is a toggle switch which cycles between ON and OFF.

This switch indicates whether or not the element faces that will
be assigned this data set will be participating in the view factor
calculations. Note: If VIEW FACTOR is ON, then the
emissivity must be given in this set. If VIEW FACTOR is OFF
and the emissivity is specified, then the ambient temperature
must also be input.

BOUNDARY CONDITIONS
INJECT
Is used to define the mass flow rate of a gas injection port to be
attached to selected
nodes in the void
region of a casting
model. This data is
used with the trapped
gas model for free
surface flow to
develop a gas over-
pressure for driving
the liquid metal.
The mass flow rate

can be given as a
constant, a function
of time, or a function
of the back pressure
that develops from
the trapped gas.
Constant: Select the Mass Flow Rate units from: {kg/sec |

g/sec | lb/sec | kg/min | g/min | lb/min}

Select the Mass Flow Rate units from: {kg/sec | g/sec |
lb/sec | kg/min | g/min | lb/min}
Enter the time values in column one and mass flow rate
Function of pressure: Select the Pressure units from the

following: {atm | psia | Ksi | lb/ft**2 | N/m**2 | Pa | KPa |
MPa | bar | dyne/cm**2}
Select the Mass Flow Rate units from: {kg/sec | g/sec |
lb/sec | kg/min | g/min | lb/min}
Enter the pressure values in column one and mass flow

rate values in column two.

BOUNDARY CONDITIONS
MAGNETIC POTENTIAL
Is used to define the prescribed magnetic potential to be applied to
selected nodes in
the model. This
type of boundary
condition is used to
set the far-field
condition for an
electromagnetic
analysis. Normally,
the potential is set to
zero all along the
outer boundary of a
model. Mesh
regions should be
extended far enough
from the induction
coils so that the far-
field condition is
satisfied.
You may enter the

Magnetic Potential as a constant or as a function of time.
Constant: Select the Magnetic Potential units from the

following: {weber/m, weber/cm, weber/mm, weber/ft,
weber/in}

Select the Magnetic Potential units from the following:
{weber/m, weber/cm, weber/mm, weber/ft, weber/in}
Enter the time values in column one and magnetic

potential values in column two

BOUNDARY CONDITIONS
MASS SOURCE
Is used to define a fluid mass source. Mass sources can be used to
create a source of
fluid without explicitly
modeling that source
in finite elements.
Mass sources can
move around inside
the model, allowing
things like retractable
nozzles to be
modeled.
To define a Mass
Source you provide
the source
temperature, the flow
rate, and the x, y, z
coordinate position.
The source temperature, flow rate, and coordinate position can be
given as a constant or a function of time.
TEMPERATURE
Constant: Select the Temperature units from: {C | F | R | K}

Select the Temperature units from: {C | F | R | K}

FLOW RATE
Constant: Select the Flow Rate from: {kg/sec | g/sec | lb/sec |
kg/min | g/min | lb/min}

Select the Flow Rate units from the following: {kg/sec |
g/sec | lb/sec | kg/min | g/min | lb/min}
Enter the time values in column one and flow rate


BOUNDARY CONDITIONS
X, Y, Z
Constant: Select the units from: {m | cm | mm | ft | in}

Select the units from: { m | cm | mm | ft | in}
MOMENTUM SOURCE
Is used to define a fluid momentum source which will impose a
pressure gradient.
Momentum sources
can be used to create
fluid motion without
requiring the object
responsible for that
motion to be
explicitly modeled in
finite elements. You
may enter the
momentum source as
a constant or as a
function of time.
Using the X, Y, Z
coordinates, you can
specify the direction
for a momentum
source. Direction can
be in any or all
coordinate directions.
The units selected will be applied to all constraint coordinate directions.
Constant: Select the Source Strength units from the following:

{N/m**3, dyne/cm**3, lb/ft**3, lb/in**3}

Select the Source Strength units from the following:
{N/m**3, dyne/cm**3, lb/ft**3, lb/in**3}
Enter the time values in column one and source

strength values in column two.

BOUNDARY CONDITIONS
POINT LOAD
is used in stress problems to define the x, y, and z loads at a point.
You may enter the point load as a constant or as a function of time.
The components of a force vector are defined using X, Y, Z

coordinates. The units selected will be applied to all coordinate
directions.
Constant: Select the Point Load units from the following: {dyne |
Newton | lb}

Select the Point Load units from the following: {dyne |
Newton | lb}
Enter the time values in column one and point load


BOUNDARY CONDITIONS
PRESSURE
is used to define the prescribed pressure to be applied to selected
nodes.
You may enter the Pressure as a constant or as a function of time.
Constant: Select the pressure units from: {N/m**2 | Pa | KPa |

MPa | bar | dyne/cm**2 | atm | psia | Ksi | lb/ft**2}

Select the pressure units from: {N/m**2 | Pa | KPa |
Enter the time values in column one and pressure


BOUNDARY CONDITIONS
SURFACE LOAD
is used in stress problems to define the x, y, and z loads at a surface.
You may enter the surface load as a constant or as a function of time.
The components of a force vector are defined using X, Y, Z

coordinates. The units selected will be applied to all coordinate
directions.
Constant: Select the Point Load units from the following: {atm,
psia, Ksi, lb/ft**2, N/m**2, Pa, KPa, MPa, bar,
dyne/cm**2}

Select the Point Load units from the following: {atm,
psia, Ksi, lb/ft**2, N/m**2, Pa, KPa, MPa, bar,
dyne/cm**2}
Enter the time values in column one and surface load


BOUNDARY CONDITIONS
SURFACE NUCLEATION
Editors Note: The Surface Nucleation boundary condition capability has not yet been
implemented in ProCAST.
When you select the SURFACE NUCLEATION menu option, the dialog
box shown here will be displayed.

BOUNDARY CONDITIONS
TEMPERATURE
is used to define the prescribed nodal temperatures. Mathematically,
this is known as a Dirichlet condition.
You may enter the Nodal Temperature as a constant or as a function of

time.
Constant: Select the temperature units from: {C | F | R | K}

Select the temperature units from: {C | F | R | K}


BOUNDARY CONDITIONS
TURBULENCE
Is used to define the turbulence quantities of intensity and characteristic
length to be assigned
to mass inflow nodes.
This boundary
condition is used with
the --- turbulence
model for high
Reynolds number
flows.
When you select

either the
INTENSITY or the
CHARACTERISTIC
LENGTH check box,
you will be presented
with an additional
option menu from
which you may
choose to enter
values for these
characteristics as a constant or as a function of time.
INTENSITY--indicates a fraction of the bulk velocity. It is the size of

the current eddy as compared to the main stream.
The default is .1 (10%).
Enter the time values in column one and intensity

CHARACTERISTIC LENGTH--specifies the length, usually, of the
opening through which the stream is flowing. The characteristic
length is usually the smallest dimension of the channel.
Constant: Select the length units from: {m | cm | mm | ft | in}

Select the length units from: {m | cm | mm | ft | in}
Enter the time values in column one and characteristic

length values in column two.

BOUNDARY CONDITIONS
VELOCITY
Is used to define a prescribed velocity to be applied to selected nodes.
Velocity can be used
to describe the Filling
Rate. If the velocity
is specified as zero it
can be used to
describe a non-slip
boundary condition.
For a 3D model, you

specify the three
components of the
direction of the
velocity by entering
values in the U, V,
and W input lines. If
you leave one of
these input lines
blank, it does not
default to a value of
zero.
For a 2D model, you

specify the U and V
components of this
direction, the W
component, if
entered, is ignored.
Even though the total magnitude of the velocity may be modified by

functions of time and/or pressure, you are required to provide these
components to indicate the orientation of the velocity vector.
Leaving one or more of the U, V, and W slots blank does not result in a
default value of zero. This is because of certain situations that arise
when it is necessary to constrain only one component by itself. For an
inlet flow particularly, all three components must be given.
The TIME and PRESSURE functions allow you to input functions of

time and pressure which modify the velocity magnitude. For example,
you might want to give a pressure function which sets an inlet velocity
to zero if the pressure exceeds a certain value. This situation might
occur if you tried to over fill a casting.
To calculate an inlet velocity magnitude; take the total volume of the

casting and rigging and divide it by the fill time to yield an inlet flow
rate. Then divide the inlet flow rate by the inlet area to give the velocity

BOUNDARY CONDITIONS
magnitude. One subtle point to be aware of is that ProCAST includes

in the inlet area total, the areas of any face that has at least one node
assigned to the inlet velocity.
Selecting the TIME and PRESSURE push buttons will open table
displays which will allow you to input these functions.
Constant: Select the velocity units from the following: {m/sec |
ft/sec | in/sec | m/min | cm/min | ft/min | in/min}

appropriate (U:, V:, and W:) input lines.
Select the velocity units from the following: {m/sec |
Enter the time values in column one and velocity

Function of pressure: Select the pressure units from: {N/m**2 |
Pa | KPa | MPa | bar | dyne/cm**2 | atm | psia | lb/ft**2}
Enter the pressure values in column one and velocity

FILL LIMIT is a slider which allows you to specify, as a percent of full,

when an inlet flow should be turned off. For example, if the fill limit is
set to 99, the inlet velocity will be set to zero magnitude when the
casting is 99% full.
You may adjust the FILL LIMIT by clicking the left mouse button on
either the right or left arrows, by clicking and dragging the slider knob to
the desired position, or by clicking the left mouse button when the
cursor is positioned over the sliders track.
A FILL LIMIT boundary condition affects the specific inlet to which it is

assigned. In the RUN PARAMETERS you may set the LVSURF
parameter to turn off all inlets in the model.

BOUNDARY CONDITIONS
VENT
Is used to describe a vent which can be attached to selected nodes on
the casting side of
the mold-metal
interface. VENT is
used with the trapped
gas model for free
surface flow during
filling transients.
The vent diameter,

effective length, and
surface roughness all
have units of length
which can be set
independently. You
click on the EXIT
PRESSURE check
box to provide the
capability to specify
the pressure as either
a constant or as a
function of time.
Select the Diameter, Length, Roughness units from: {m | cm |

mm | ft | in}

appropriate input lines.
Constant: Select the Pressure units from: {atm | psia | Ksi |
lb/ft**2 | N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2}

Select the Pressure units from: {atm | psia | Ksi | lb/ft**2
| N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2}
Enter the time values in column one and exit pressure


BOUNDARY CONDITIONS
VOLUMETRIC HEAT
Is used to define a volumetric heat source or sink. A positive value is
used to describe a
heat source and a
negative value to
describe a heat sink.
You may specify the

Volumetric Heat as a
constant or as a
function of TIME
and/or
TEMPERATURE.
The time function

modifies the
constant value
specified.
Accordingly, if you
use either of these
options, the constant
value you provide
will be used. The
default constant value is 1.0.
Constant: Select the Volumetric Heat units from: {W/m**3 |

cal/cc/sec | Btu/ft**3/sec | Btu/in**3/sec | cal/cc/min |
Btu/ft**3/min | Btu/in**3/min}

Enter the time values in column one and heat modifier

Function of temperature: Select the Temperature units from:
{C | F | R | K}
Enter the temperature values in column one and heat

modifier values in column two.
Remarks None.

BOUNDARY CONDITIONS
BOUNDARY
ASSIGN SURFACE
Description ASSIGN SURFACE is a push button in the BOUNDARY menu. It

provides the capability to select element faces or nodes, combine them
into sets, and associate properties from the boundary condition
database with these sets in the model.
Method ASSIGN SURFACE is activated by clicking on it. This results in the

immediate action to display a table containing a list of any boundary
condition node or face sets which have been defined in the model and
their Boundary Condition
assignment, if any.
Some boundary
conditions are applied to
nodes, others to faces.
A Boundary Condition
Set may contain nodes
or faces but not both.
PreCAST selects nodes
or faces according to the
Boundary Condition
type.
ASSIGN SURFACE also

displays a table of the
boundary conditions in
the database. These
two table displays are
separated by a group of
tools with which you may
select element faces and
nodes and create group
sets. The figure shown
here illustrates a display
for a model with several
group sets, the Toolbox,
and the Boundary
Condition Database
entries.

BOUNDARY CONDITIONS
The background of a table entry, in either table, will be highlighted in

red when it is selected. Group sets or element faces will be drawn in
red in the work window pane when their respective set entry is selected.
If you created boundary condition sets in the mesh generation package,

such as PATRAN or IDEAS, these sets would appear in the top table
display.
To assign a boundary condition to a group set:

1. Select the set by clicking the desired entry in the Assignment Table.
2. Select a boundary condition from the database by moving the cursor
down to the window displaying the Boundary Condition
Database entries. If the Boundary Condition you want is not
visible in the table at first, you may scroll to the desired entry.
3. When you have located the desired boundary condition entry, click
on it.
4. ASSIGN the boundary condition data to the group by clicking the
ASSIGN push button in the Toolbox. This will place the
Boundary Condition key word and ID# in column two of the
Assignment Table.
To associate boundary conditions with other group sets or element

faces, repeat steps one through four.
PreCAST also provides the capability to create boundary condition sets.

The Toolbox contains the tools you use to create these boundary
condition sets. Each tool is represented in the Toolbox as a push
button, which may be activated by clicking the left mouse when the
cursor is over the corresponding tool. Each of these tools will be
described here. For convenience of presentation, they will be described

BOUNDARY CONDITIONS
ADD--creates a Boundary Condition

group set entry in the
Assignment Table. When
this tool is selected, it opens
a menu, as shown here,
listing each type of boundary
condition.
Select the type of boundary

condition to be described by
clicking on the desired
condition. Clicking on a
choice from this menu will
result in the immediate action
to create an entry in the
Assignment Table and close
the menu. In the figure
shown above, item number
six, Turbulence, was added to
this table because the
corresponding choice was
made from the menu at the
right.
It is important to note, that at

this point in the process a
group set entry has been
created in the assignment
table. However, nodes or
faces have not yet been
assigned to this entry and no
boundary condition properties
have been assigned.
Each of these boundary conditions and their respective

properties are discussed in the Boundary Conditions Section of
this manual.
ASSIGN--associates a boundary condition database entry with a

specific boundary condition group set. To make an
assignment, follow the four step procedure described above.
Please note that the type of data that you select from the
database must agree with the type of group set.

BOUNDARY CONDITIONS
COPY--enables you to copy the contents of one group set to another.

This is useful, for example, when you want to apply
temperature and velocity conditions to the same nodes. To
copy a group set, click on the group set table entry you want to
copy and then click on the COPY push button.
There are some restrictions on the COPY operation, depending

upon the type of sets involved. You may copy from any nodal
boundary condition set to any other nodal set or from any
element face boundary condition set to any nodal set.
However, you may not copy from nodal sets to face sets.
DELETE--removes a Boundary Condition group set entry from the

Assignment Table. To remove a group set, select the desired
entry in the Assignment Table by clicking on it. This will
highlight the selected entry in red. Once the desired set entry
has been highlighted, click on the DELETE push button. This
will remove the entry from the table and remove the association
of any nodes which were stored in this entry. DELETE does not
remove nodes from the model.
DESELECT--provides the capability to untag faces or nodes in a

manner similar to the selection process. To deselect faces or
nodes, click on the DESELECT push button. Then drag the
cursor over the desired nodes or faces while holding the left
mouse button down. You may also create a drag box to
enclose a portion of the model by depressing and holding the
right mouse button while dragging the cursor to form a box
around the desired portion of the model. The SURFACE option
will also work for deselection.
INTERFACE--provides the capability to tag all faces which are on the

interface. This is particularly helpful in die casting for selecting
inner surfaces.
LINK--provides the capability to establish the relationship between two

PERIODIC boundary condition node sets. LINK is used after
two PERIODIC node sets have been created (using the ADD
tool) and after nodes have been assigned to each of these
entries.
To LINK two PERIODIC node sets, select one of the sets from
the Assignment Table by clicking on it. The selected entry will
be highlighted with a red background. Next, click on the LINK
push button in the toolbox. The push button will be highlighted
with a red background. Move the cursor to the Assignment
Table and select the companion set. The second table entry
will be highlighted with a green background and PreCAST will

BOUNDARY CONDITIONS
display a Rotation and Transformation Input Display. This is

illustrated in the figure shown here.
In the input lines, enter the X, Y, and Z coordinates of two

points which define an axis of rotation and give the rotation
angle in degrees.
You can also input a translation vector by entering the

coordinates of the translation in the DX, DY, and DZ input lines.
Click on the EXECUTE push button in the input display and

PreCAST automatically computes a tolerance value based
upon the geometry and determines if the nodes of the two sets
match up with the specified transformation.
REMAINDER--allows you to tag any free faces which are not a part of
any other similar boundary condition.
SELECT--allows you to tag surfaces for assignment to a boundary

condition set. To select faces or nodes, click on the SELECT
push button after clicking on the intended boundary condition
set in the Assignment Table.
To select faces or nodes, drag the cursor over the desired

surfaces or node(s) while holding the left mouse button down.
You may also create a drag box to enclose a portion of the
model by depressing and holding the right mouse button while
dragging the cursor. Once a surface has been selected, its
edges will be highlighted in red in the work window pane and
the STORE push button in the Toolbox will be highlighted with
a blue background to indicate that some faces have been
selected but not stored.
When triangular faces are selected, the centroid is indicated

with a red dot. When quadrilateral faces are selected, the
diagonals are drawn in red.
SELECT ALL--tags all of the external faces or nodes in the problem .

BOUNDARY CONDITIONS
Once a face or node has been selected, its edges will be

highlighted in red in the work window pane and the STORE
push button in the Toolbox will be highlighted with a blue
background to indicate that some faces have been selected but
not stored. Any faces which were previously assigned to a
SYMMETRY set will not be tagged by SELECT ALL.
Before using SELECT ALL, you should click on the boundary

condition set in the Assignment Table where you intend to
STORE the selected surfaces or nodes.
STORE--places the selected surfaces or nodes into a boundary

condition set in the Assignment Table. Once you have tagged
all the faces or nodes that you want to be in the set, click on the
STORE push button in the Toolbox. This will store the selected
information in the table and restore the background color of the
STORE push button.
SURFACE--provides the capability to select all faces or nodes of a

specific surface once you
have selected one face on
the surface. After selecting
one face on a surface, click
on the SURFACE push
button in the Toolbox.
PreCAST will open an input dialog box similar to the one shown
here. Move the cursor to the input line and type a tolerance
angle. Click on the APPLY push button in the dialog box and
PreCAST will select adjacent faces whose angles between
normals are less than the tolerance you specified.

BOUNDARY CONDITIONS
Remarks SYMMETRY face set and PERIODIC Boundary Condition Node Sets
do not require assignments from the boundary condition database.
Periodic boundary conditions are handled by creating two PERIODIC
sets. For a given pair, the nodes of one set must match up closely to
the nodes of the other set after undergoing a specified rotation and
translation.
You may use the view tools, such as rotate, zoom, move, etc., to
manipulate the model in the work window pane to make it easier for you
to make your selections.
You may examine and/or modify the boundary condition properties for
Boundary Condition Database entries by clicking the READ/MODIFY
push button in the Boundary Condition Database display window. This
will display a Boundary Condition Description Display appropriate to the
type of boundary condition selected. The BOUNDARY CONDITIONS--
DATABASE section of this manual explains the types of boundary
conditions and their parameters and attributes.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE, BOUNDARY

CONDITIONS--DATABASE

BOUNDARY CONDITIONS
BOUNDARY CONDITION
ASSIGN VOLUME
Description ASSIGN VOLUME is a push button in the BOUNDARY CONDITION

menu. It provides the capability to associate properties from the
boundary condition database with specific material regions in the
model.
Method ASSIGN VOLUME is activated by clicking on it. This results in the

immediate action to display a
menu which lists the types of
boundary conditions which may
be assigned. The figure shown
here illustrates this option menu.
When you select an option from

this menu by clicking the desired
push button, PreCAST will
display an appropriate
combination of table displays.
The figure shown here, for HEAT,
is an example of these displays.
The display for each option in the
menu will be similar to this one,
with the difference being the
content in the boundary condition
database display table.
The top-most table will contain a

list of all the material IDs in the
model and the material names
which have been assigned to
them. Any material ID that has
no assignment will have an
asterisk * in the VOL ASSIGN
column. When you click on a
table entry its background will be
highlighted in red and the
elements with the corresponding
material ID will be drawn in green
in the work window pane. The
bottom-most table will contain a
list of all the Boundary Conditions
in the database which correspond
to the option you selected.
The procedure for associating

BOUNDARY CONDITIONS
boundary conditions with material regions is the same for each of the
optional types of boundary conditions shown in this menu. To assign a
boundary condition to a material region:
1. Select the Material by clicking the desired entry in the
Assignment Table.
2. Select a boundary condition from the database by moving the
cursor down to the window displaying the Boundary Condition
Database entries. If the Boundary Condition you want is not
visible in the table at first, you may scroll to the desired entry.
3. When you have located the desired boundary condition entry,
click on it.
4. ASSIGN the boundary condition to the material region by clicking
the ASSIGN push button in the Assignment Table. This will
place the Boundary Condition ID# in column three of the
Assignment Table.
To associate boundary conditions with other material regions, repeat

steps one through four.
You can remove any assignment by selecting the desired row in the
Assignment Table and clicking the CANCEL push button in that table
display.
You may click on the QUIT push button at any time to close option
menu or the table displays.
CURRENT DENSITY--allows you to assign current densities from the

boundary condition database to specific material ID numbers.
MASS SOURCE--allows you to assign mass sources from the boundary

condition database to specific material ID numbers. If a mass
source changes its position over time, just choose the material
ID that it starts in. It is not necessary to include all the material
IDs that it might travel through.
MOMENTUM SOURCE--allows you to assign momentum sources from

the boundary condition database to specific material ID
numbers.
SURFACE HEAT--allows you to assign heat functions from the

boundary condition database to specific material ID numbers.
This applies a Heat Boundary Gondition to the free surface of a
fluid.
VOLUMETRIC HEAT--allows you to assign volumetric heat functions

from the boundary condition database to specific material ID
numbers.

BOUNDARY CONDITIONS
Remarks You may use the view tools, such as rotate, zoom, move, etc., to
You may examine and/or modify the boundary condition properties for
Boundary Condition Database entries by clicking the READ/MODIFY
push button in the Boundary Condition Database display window. This
will display a Boundary Condition Description Display appropriate to the
type of boundary condition selected. The BOUNDARY CONDITIONS--
DATABASE section of this manual explains the types of boundary
conditions and their parameters and attributes.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE, BOUNDARY

CONDITIONS--DATABASE

BOUNDARY CONDITIONS
BOUNDARY
PERMEABILITY
Description PERMEABILITY is a push button in the BOUNDARY menu. It provides
the capability to account for trapped gas which escapes through the
mold by assigning permeabilities to specific mold material regions in
the model. Permeability is primarily intended for sand or shell molds.
Method PERMEABILITY is
activated by clicking on it.
This results in the
immediate action to
display a table which lists
all of the material IDs in
the model.
When you select a

material name from this
list, the background for
that row is highlighted in
red and the elements with
that material ID are
redrawn in green in the
work window pane. This
is to aid you in identifying
the location of each material ID.
To assign a permeability to a material region:

1. Select the Material by clicking the desired entry in the
Assignment Table.
2. Move the cursor to the Edit Value input line.
3. Type the desired value and press ENTER.
4. Select the desired units of measure. The right-most column of
each entry in this display contains the units of measure. This is
a rotary toggle switch. Successive clicks on this switch will
cycle you through the available options. You may chose from:
{m**2 | cm**2 | mm**2 | ft**2 | in**2}
You can remove any assignment by selecting the desired row in the
Assignment Table and entering a value of zero in the Edit Value input
line. You may click on the QUIT push button at any time to close this
display.
Remarks None.
BOUNDARY
BOUNDARY CONDITIONS
INVERSE
Description INVERSE is a push button in the BOUNDARY menu which allows you
to select the HEAT boundary conditions in the model for which the Film
Coefficient, Flux, and Emissivity properties will be calculated using the
inverse calculation method. These calculations will be based upon the
geometry, initial conditions, boundary conditions, and thermal history.
Method INVERSE is activated by clicking on it.

display a table listing the HEAT boundary
conditions in the model. The figure
shown here illustrates this display.
As shown in this figure, there are three

columns on the right side of the table.
The headings are: H--Film Coefficient, Q-
-Flux, and E--Emissivity. Beneath these
headings are rows of toggle switches.
There is one row of switches for each
HEAT boundary condition in the table. You specify the properties for
each boundary condition which are to be calculated using the inverse
calculation method by toggling the corresponding switch to the Y or yes
position.
Remarks You may perform an inverse calculation on all H, Q, and E values, as

well as for different HEAT boundary conditions at the same time. You
may also calculate these boundary conditions using the inverse method
in conjunction with Interface--Inverse.
Related Topics BOUNDARY CONDITIONS

BOUNDARY CONDITIONS
RADIATION
Description RADIATION is a push button in the Main Function Banner. This
function of PreCAST enables you to describe radiation data and apply
them to enclosures and moving solids. When you activate the
RADIATION push button, a menu is opened which allows you to work
with the various capabilities associated with RADIATION. Selections
from the menu provide access to these capabilities and will be
Method RADIATION is activated by clicking on it. The initial menu is shown

changing or deleting radiation information
in the database. These may be used in your model and the analysis to
be performed.
You may leave the RADIATION function by clicking another push

Remarks The major capabilities of the RADIATION function of PreCAST will be

this manual.
DATABASE
Provides the data management functions for radiation
information. You may describe attributes for Emissivity,
Temperature, and Velocity and how these factors are to be
applied in your model. DATABASE allows you to add, delete,
copy, and modify entries in the radiation database.
ENCLOSURE
Provides the capability to select enclosure faces, combine them
into sets, and assign emissivity, temperature, and velocity data
to each set.
SOLID
Provides the capability to assign velocities to solid elements.
When you select from the RADIATION menu, ProCASTs graphical

user interface provides a straight forward and simple procedure for
working with the various databases used by ProCAST. This database
facility is described elsewhere in this manual. You should read about
this facility before attempting to modify the radiation database.

BOUNDARY CONDITIONS
RADIATION
DATABASE
Description DATABASE is a push button in the RADIATION menu which accesses

the Radiation Database. Using ProCASTs DATABASE FACILITY you
may create, delete, or modify radiation information in the database.
This radiation information may then be used for simulation and
analysis.
Method DATABASE is activated by clicking the on it. This results in the

immediate action to display a table containing any radiation data entries
which may be in the database. The figure shown here illustrates such a
display.
PreCAST allows you

to Read, Add, Copy,
and Delete radiation
information from the
Radiation Database.
These capabilities
are described in the
DATABASE
FACILITY section of
this manual. You
the TABLE
MAINTENANCE
section of this
manual which
describes ProCASTs
graphical interface
for maintaining
tables.
This section will discuss the requirements for adding radiation

information to the database and how you specify individual properties
and attributes for each entry.
To add a radiation entry to the database, click on the ADD push button
in the Radiation Database display. This will result in the immediate
action to open a sub-menu which lists
the radiation attributes which may be
described. This sub-menu is shown
below.
The characteristics, properties, and

methods for defining radiation

BOUNDARY CONDITIONS
information may vary from one attribute to another.
When you choose from this menu, PreCAST will display the appropriate
input form and options as shown below. For convenience of illustration,
the example shown is the result of selecting the EMISSIVITY option
from the sub-menu.
PreCAST also displays an option box above the Radiation Description

display. The content of the option box depends upon the radiation
attribute you selected. The option box may contain properties or
options which are displayed as a group of push buttons, text input lines,
or a combination of these. In this case, emissivity may be designated
as a CONSTANT or as a linear function of TEMPERATURE.
Therefore, there are corresponding push buttons in the option box.
If the option box includes

a text input line, enter
data in a text input line by
placing the cursor in the
text box, typing the
desired data, and
pressing ENTER. In some
cases, the text input line
will be accompanied by a
rotary toggle switch.
These toggle switches
allow you to choose the
desired value from a list
of options. Successive
clicks on the toggle
switch will cycle through
the available options.
minimum requirement for adding a radiation entry to the database is to
give it a keyword name and define its properties.
All of the radiation descriptions have two input text lines in common:
KEYWORD and COMMENTS. Other properties, which may be
defined, depend upon the type of radiation attribute selected.
these descriptions, the individual options for each available radiation
attribute are discussed.
KEYWORD: Enter the name you want to give the radiation database

BOUNDARY CONDITIONS
entry. The key word must begin with an alphabetic character

and may include upper and lower case characters.
COMMENTS: This portion of the Radiation Description is a free format

text box which may be used to annotate the radiation attribute.
For example, you may want to describe the sources for any
property data or techniques used to develop the radiation
information or its method of application.
When you select the method for describing an attribute PreCAST

dynamically displays the appropriate property names, option boxes, and
input text lines.
contain a rotary
units of measure.
toggle through the
When you click on the APPLY push button or press ENTER, the data
entered will be stored, and the dialog box will be closed.
without saving the
data.
Selecting TIME or
TEMPERATURE
results in the
immediate action to
display an input table.
This table, like the
dialog box for a
constant, may contain
rotary toggle switches
for the units of
measure. As shown in
this example for
Emissivity, there are
two toggle switches
which also serve as
the column sub-
headings for the table.

BOUNDARY CONDITIONS

table and move the cursor to the next available table entry. When you
are satisfied with the table entries, click on the STORE push button, the
data in the table will be stored, and the dialog box will be closed.
The syntax and options available for each type of radiation attribute are
discussed below. For convenience of presentation, these are presented

BOUNDARY CONDITIONS
EMISSIVITY
Is used to enter an emissivity value as a constant or as a function of
temperature. These emissivities will be applied to enclosure faces.
Enclosure faces are required to have an emissivity value if they are to

participate in a view factor radiation solution. The CONSTANT and
TEMPERATURE values are mutually exclusive. If you STORE either
one, its respective push button will be highlighted in blue to indicate that
data has been entered and saved.
Function of temperature: Select the temperature units from: {C |

F | K | R}
Enter the temperature values in column one and

emissivity values in column two.

BOUNDARY CONDITIONS
TEMPERATURE
Is used to define temperatures which will be assigned to enclosure
faces. Enclosure faces are required to have a temperature value if they
are to participate in a view factor radiation solution.
You may define the temperature as a CONSTANT value or as a linear

function of TIME. The CONSTANT and TIME values are mutually
exclusive. If you STORE either one, its respective push button will be
highlighted in blue to indicate that data has been entered and saved.
Constant: Select the temperature units from: {C | F | R | K}

Select the temperature units from: {C | F | R | K}


BOUNDARY CONDITIONS
VELOCITY
Is used to define the x, y, z direction of a velocity which may be applied
to an enclosure or to solid
elements in the model. It
also allows you to
describe the magnitude of
this velocity as a function
of time. This is used in
the radiation model when
you have a furnace,
baffles, or other parts
moving relative to the
casting. A single crystal
investment casting is an
example.
You may enter velocity as

a constant or as a
default value for any
component is zero. The
time function will multiply
the magnitude of the
velocity vector.
Constant: Select the velocity units from the following: {m/sec |


Enter the time values in column one and velocity

Remarks None.

BOUNDARY CONDITIONS
RADIATION
ENCLOSURE
Description ENCLOSURE is a push button in the RADIATION menu. It provides

the capability to select enclosure faces, combine them into sets, and
assign emissivity, temperature, and velocity data to each set in the
model.
Method ENCLOSURE is activated by clicking on it. This results in the

immediate action to display a table containing a list of any enclosure
element sets which have been defined in the model and the emissivity,
temperature, and/or
velocity attributes which
have been assigned, if
any. A table of the
radiation attributes in the
database is also
displayed. These two
table displays are
separated by a group of
tools with which you may
select enclosure faces
and create element sets.
The figure shown here

illustrates these two table
displays and the Toolbox.
The background of a
table entry, in either
table, will be highlighted
in red when it is selected.
Element sets will be
drawn in red in the work
window pane when their
respective set entry is
selected.

BOUNDARY CONDITIONS
To assign a radiation attribute to an element set:

1. Select the set by clicking on the desired entry in the Assignment
Table.
2. Select a radiation attribute from the database by moving the cursor
down to the window displaying the Radiation Database entries.
If the Radiation entry you want is not visible in the table at first,
you may scroll to the desired entry.
3. When you have located the desired radiation attribute entry, click on
it.
4. ASSIGN the attribute to the element set by clicking the ASSIGN
push button in the Toolbox. This will place the radiation
attribute ID# in the appropriate column (E, T, or V) of the
Assignment Table.
To associate radiation attributes with element sets, repeat steps one

through four.
PreCAST also provides the capability to create enclosure face element

sets. The Toolbox contains the tools you use to create these sets.
Each tool is represented in the Toolbox as a push button which may be
activated by clicking the left mouse button. Each of these tools will be
described here. For convenience of presentation, they will be described
ADD--creates an enclosure face element set entry in the Assignment

Table. When this tool is selected, an empty row is added to the
Assignment Table. An asterisk * will be placed in each
column (E, T, V) to indicate that no data has been assigned to
that entry.
It is important to note that at this point in the process the

element set entry has been created in the assignment table.
However, elements have not yet been assigned to this entry
and no radiation attributes have been assigned.
Each of these radiation attributes and their respective

properties are discussed in the Radiation Section of this
manual.
ASSIGN--associates a radiation database entry with a specific

enclosure element set. To make an assignment, follow the four
step procedure described above.
CANCEL--allows you to close the ENCLOSURE displays.

BOUNDARY CONDITIONS
DELETE--removes all enclosure elements from the set an enclosure

face element set entry from the Assignment Table. To remove
an element set, select the desired entry in the Assignment
Table by clicking on it. This will highlight the selected entry in
red. Once the desired set entry has been highlighted, click on
the DELETE push button. This will remove the entry from the
table and disassociate any elements which were stored in this
entry. DELETE does not remove elements or nodes from the
model. To complete the deletion you must click on the STORE
push button.
DESELECT--provides the capability to untag faces in a manner similar

to the selection process. To deselect faces click on the
DESELECT push button. Then drag the cursor over the
desired face(s) while holding the left mouse button down. You
may also create a drag box to enclose a portion of the model by
depressing and holding the right mouse button while dragging
the cursor to form a box around the desired portion of the
model.
SELECT--allows you to tag faces for assignment to an enclosure

element set. To select faces click on the SELECT push button
after clicking on the intended element set in the Assignment
Table.
To select faces, drag the cursor over the desired surfaces while
holding the left mouse button down. You may also create a
drag box to enclose a portion of the model by depressing and
holding the right mouse button while dragging the cursor to
form a box. Once a surface has been selected, its edges will
be highlighted in red in the work window pane and the STORE
push button in the Toolbox will be highlighted with a blue
background to indicate that some faces have been selected but
not stored.
Once you release the mouse button, you need to click on

SELECT again if you wish to choose more faces.
SELECT ALL--tags all of the free enclosure faces in the problem .

Once a face has been selected, its edges will be highlighted in
red in the work window pane and the STORE push button in the
Toolbox will be highlighted with a blue background to indicate
that some faces have been selected but not stored.
Before using SELECT ALL, you should click on the enclosure

set in the Assignment Table where you intend to STORE the
selected surface elements.

BOUNDARY CONDITIONS
STORE--places the selected surfaces into an enclosure element set in

the Assignment Table. Once you have tagged all the faces that
you want to be in the set, click on the STORE push button in
the Toolbox. This will store the selected information in the
table and restore the background color of the STORE push
button.
Remarks At a minimum, you must assign emissivity and temperature data to

each element set. If the faces in the set are moving relative to the
casting, then you need to assign a velocity as well.
You may use the view tools, such as rotate, zoom, move, etc., to
You may examine and/or modify the entries in the Radiation Database
by clicking the READ/MODIFY push button in the Radiation Database
display window. This will display a Radiation Description Display
appropriate to the type of radiation attribute selected. The RADIATION-
-DATABASE section of this manual explains the types of radiation
attributes and their parameters.
You should also assign ALL enclosure elements to a set or you will
receive warning messages from DataCAST.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE, RADIATION--

DATABASE

BOUNDARY CONDITIONS
RADIATION
SOLID
Description SOLID is a push button in the RADIATION menu. It provides the

capability to assign velocities to solid elements in the model.
Method SOLID is activated by clicking on it. This results in the immediate

velocities in the
Radiation Database.
The figure shown
here illustrates a
display for a model
with three material
regions.
When you select an

entry from this table
by clicking on the
ID#, the elements in
the model with a
corresponding ID
in the work window
pane in green.
To assign a velocity
to a region of the
model:
1. Select the region
by clicking on
the desired
table entry.
2. Select a velocity
from the
database by
moving the
cursor down
to the window
displaying
the
RADIATION
DATABASE
entries. If
the velocity
you want is

BOUNDARY CONDITIONS
not visible in the table at first, you may scroll to the desired
entry.
3. When you have located the desired velocity entry, click on it.
4. ASSIGN the velocity to the region by clicking the ASSIGN push
button. This will place the velocitys database sequence
number in the VELOCITY column of the Assignment Table.
To associate velocities with other regions, repeat steps one through

four.
button in the Velocity Assignment table or select any push button in the
Main Function Banner. This will store the assignments and close the
display.
Remarks Assigning velocities to solid elements in the model may be used, for
example, for baffles which are moving relative to a casting, where you
want to solve for the temperatures in the baffles rather than impose
them. You may also construct an entire furnace out of solid elements
rather than use enclosure elements.
Emissivities for the solid elements would be applied as a heat

BOUNDARY CONDITION.
If you have two groups of solid elements which are moving relative to
one another, it is best to apply the velocity to the group with the least
number of elements. This minimizes the size of some output files.
You may examine and/or modify the properties for Radiation Database
entries by clicking the READ/MODIFY push button in the Radiation
Database display window. This will display the Radiation Description
for the selected table entry. Further use of this capability is explained
in the RADIATION DATABASE section of this manual.
Related Topics DATABASE FACILITY, TABLE MAINTENANCE, RADIATION--

DATABASE

INITIAL CONDITIONS
INITIAL CONDITIONS
Description INITIAL COND is a push button in the Main Function Banner. This
function of PreCAST enables you to assign initial temperatures to each
material ID in the model or extract the initial temperatures from a
previous run of ProCAST. Additionally, the FREE SURFACE option in
the INITIAL CONDITIONS menu allows you to indicate which volumes
in the mesh are initially empty in free surface fluid problems. When
you activate the INITIAL CONDITIONS push button, a menu is opened
which allows you to work with the various capabilities associated with
INITIAL CONDITIONS. Selections from the menu provide access to
these capabilities and will be discussed in this section.
Method INITIAL CONDITIONS is activated by clicking on it. It displays the

menu shown here. When you select a
function from this menu PreCAST will
display additional Dialog Boxes, Option
Lists, Data Input Windows, or sub-menus.
changing or deleting radiation information
in the database. These may be used in your model and the analysis to
be performed.
You may leave the INITIAL CONDITIONS function by clicking another

push button in the Main Function Banner.
Remarks The major capabilities of the INITIAL CONDITIONS function of

PreCAST will be summarized here. Each capability will be described in
greater detail in this manual.
CONSTANT
Provides the capability to specify an initial temperature for each
material ID in the model.
EXTRACT
Provides the capability to pull nodal temperatures for a set of
materials IDs at a given time step from a previous results file.
This is particularly useful in die casting or permanent mold
simulations when you want to determine the temperature in the
mold after several cycles. Extracted temperatures override
initial temperatures.

INITIAL CONDITIONS
FREE SURFACE
Provides the capability to specify the material volumes which
are initially empty. This is only necessary if you are setting up
a free surface fluid flow problem.
When you select from the INITIAL CONDITIONS menu, ProCASTs

graphical user interface provides a straight forward and simple
procedure for working with the parameters and attributes associated
with the initial temperature conditions in the model.

INITIAL CONDITIONS
INITIAL CONDITIONS
CONSTANT
Description CONSTANT is a push button in the INITIAL CONDITIONS menu. It
provides the capability to assign temperatures to material regions in the
model.
Method CONSTANT is activated by clicking on it. This results in the immediate

have been defined in the model. It also displays an Edit Value input
line. The figure shown
here illustrates a display
for a model with three
material regions.
When you select an entry

from this table by clicking
on the ID#, the
background of that row is
highlighted in red and the
elements in the model
with a corresponding ID
number will be drawn in
green in the work window
pane.
To assign an initial
constant temperature to a
region of the model:
2. Enter the temperature by moving the cursor to the Edit Value input
line. Type the desired value and press ENTER.
3. Select the temperature units by clicking on the UNITS toggle switch.
This is a rotary toggle, successive clicks on it will cycle you
through the available options. These options are {C | F | R | K}.
To assign temperatures to other regions, repeat steps one through

three.
You close the display and move to another function of PreCAST or to

another function of INITIAL CONDITIONS by clicking the appropriate
Main Function Banner or Menu push button respectively.
Remarks You must specify the initial conditions in the mold.
INITIAL CONDITIONS
INITIAL CONDITIONS
EXTRACT
Description EXTRACT is a push button in the INITIAL CONDITIONS menu. It

provides the capability to assign nodal temperatures to material regions
in the model by loading them from a previous simulation results file at
the specific time step you designate.
Method EXTRACT is activated by clicking on it. This results in the immediate

have been defined in the model. It also displays an Extract Parameters
Input dialog box. The
figure shown here
illustrates a display
material regions.
When you select an

by clicking on the
ID#, the background
of that row is
highlighted in red and
the elements in the
model with a
corresponding ID
in green in the work
window pane.
In this table, any

material which has
already been
assigned an initial
value will be
highlighted with a
blue background.
To extract initial temperatures for a region of the model:

2. Enter the full path name of the directory where the results file can be
found by moving the cursor to the Enter Directory name input
line. Type the desired value and press ENTER. If the results
are in the current directory, you may enter a period and press
ENTER.
3. Enter the prefix that was used for the results file you want to use by
moving the cursor to the Prefix input line. Type the desired
value and press ENTER. PreCAST will append t.unf to the prefix

INITIAL CONDITIONS
to make a complete file name.

4. Enter the time step number that you want to use as the source of the
temperatures for this model by moving the cursor to the Enter
Step value input line. Type the desired value and press ENTER.
Note: There must be results in the file for the time step you
specify. For example, if TFREQ = 5 in the solution file you
indicated, the time step you enter must be some multiple of 5.
5. When you are satisfied with the Path, Prefix, Step value entries,
click on the APPLY push button in the Extract Parameters Input
dialog box. This will place the prefix and step number in the
appropriate columns in the list of the materials.
To extract temperatures for other regions, repeat steps one through

five.
Once you have applied the Path, Prefix, and Step value entries, as
discussed in step 5 above, you may look at the values in the results file
by clicking the DISPLAY push button in the Extract Parameters Input
dialog box.

Remarks EXTRACT is particularly useful in die casting or permanent mold

simulations when you want to determine the temperature in the mold
after several cycles.
Related Topics INITIAL CONDITIONS--CONSTANT

RUN PARAMETERS
INITIAL CONDITIONS
FREE SURFACE
Description FREE SURFACE is a push button in the INITIAL CONDITIONS menu.

It provides the capability to specify material regions in the model which
are initially empty.
Method FREE SURFACE is activated by clicking on it. This results in the

immediate action to display a table containing a list of the material
regions which have been defined in the model. The figure shown here
illustrates a display
material regions.
When you select an

by clicking on the
ID#, the background
of that row is
highlighted in red and
the elements in the
model with a
corresponding ID
in green in the work
window pane.
Material regions in this table which are specified to be initially empty will
display the word YES in the EMPTY column of this table.
To specify that a material region is initially empty, toggle the EMPTY

switch in that row to the desired YES or NO position.
Repeat these two steps for each region of the model which is initially
empty.

Remarks FREE SURFACE is only necessary when you are setting up a free
surface fluid flow problem. For flow through a filter, you should specify
that the filter is initially empty.
Related Topics
RUN PARAMETERS
RUN PARAMETERS
Description RUN PARAMETERS is a push button in the Main Function Banner.

This function of PreCAST enables you to specify run parameters for the
various types of analyses to be performed. Selections from the menu
provide access to the available sets of run parameters in ProCAST.
This section will discuss these capabilities and how to use them.
Method RUN PARAMETERS is activated by clicking on it. It displays the menu

shown here. When you select a function
from this menu PreCAST will display
additional Dialog Boxes. These graphical
interface tools will guide you through the
process of specifying or changing
individual run parameters.
You may leave the RUN PARAMETERS

function by clicking another push button
in the Main Function Banner.
Remarks The RUN PARAMETERS function of

PreCAST provides the capability to specify which ProCAST capabilities
will be used during the simulation, how they will be used, and other
general parameters which will govern the simulation.
The names of most frequently changed parameters will be displayed in

black. The names of the more advanced or infrequently changed
parameters will be displayed in red. Next to selected parameters is a
rotary toggle switch which will display the available units for that
specific parameter. Successive clicks on these toggle switches will
cycle through the available options.
To enter or change a value for a parameter, place the cursor in the

desired parameter input box, type the value, and press ENTER.

RUN PARAMETERS
Information about each parameter is available on-line. To obtain

information about a parameter, place the cursor in the desired
parameter input box and click on the HELP push button. HELP will
display an information window. You close the information window by
clicking the QUIT push button in the HELP window.
For a specific job, as indicated by the file prefix, PreCAST displays the
default values for the run parameters, in the dialog box, until you make
a change for that job. If you change a parameter and subsequently
RESTART the job, PreCAST will read the prefixp.dat file and use the
parameter values which have been saved there as the defaults.

RUN PARAMETERS
RUN PARAMETERS
UNITS
Description UNITS is a push button in the RUN PARAMETERS menu. It provides
the capability to specify the default units of measure to be used in the
output files.
Method UNITS is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the unit of measure
types. Next to each category of units is a rotary toggle switch which will
display the available
options for each of the
categories. Successive
clicks on these toggle
switches will cycle through
the available options.
The figure shown here

illustrates the UNITS
dialog box. The UNITS
parameters and the
available options for each
parameter will be presented here. For convenience in presentation,
they will be presented in alphabetical order.
PUNITS--specifies the pressure units to be used in the outputs.

Choose from: {N/m**2 | Pa | KPa | MPa | bar | dyne/cm**2 | atm
| psia | Ksi | lb/ft**2}
QUNITS--specifies the heat flux units to be used in the outputs.
Choose from: { W/m**2 | cal/cm**2/sec | cal/mm**2/sec |
Btu/ft**2/sec | Btu/in**2/sec | cal/cm**2/min | cal/mm**2/min |
TCUNITS--specifies the thermocouple units to be used in the outputs
and is only used for inverse modeling.
Choose from: {C | F | R | K}
TUNITS--specifies the temperature units to be used in the outputs.
VUNITS--specifies the velocity units to be used in the outputs.
Choose from: {m/sec | cm/sec | mm/sec | ft/sec | in /sec | m/min
| cm/min | mm/min | ft/min | in/min}
You may close this display and move to another function of PreCAST
or to another function of RUN PARAMETERS by clicking the
appropriate Main Function Banner or Menu push button respectively.
Remarks None.
Related Topics

RUN PARAMETERS
RUN PARAMETERS
GENERAL
Description GENERAL is a push button in the RUN PARAMETERS menu. It

provides the capability to control the time stepping algorithm and the
type of output to be produced during the simulation.
Method GENERAL is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the general parameters
and, if applicable, units associated with a parameter.
The figure shown above illustrates the GENERAL dialog box. Just
below the GENERAL dialog box is a COMMENTS input line. This box
allows you to enter your own comments about this job. The comments
you enter will be stored in the prefixp.out file. To enter comments,
place the cursor in the input line, type your comments, and press
ENTER.
The GENERAL parameters and the available options for each

parameter will be discussed here. For convenience in presentation,

RUN PARAMETERS
AVEPROP--specifies the method to be used in calculating the

properties for each element. ProCAST will calculate the
properties at each Gauss point or you may specify that the
properties be calculated only at the element center and that this
value will be used as an average for the whole element. This
averaging reduces, somewhat, the finite element integration
time required. This averaging does not apply to the specific
heat or enthalpy calculations.
Choose from:
{0 to calculate at each point, or
1 to use the average}
The default is 0.
CGSQ--specifies the Conjugate Gradient Squared solver flag. The

values specified in this parameter may be added together. This
allows you to build a customized solver approach for your
simulation.
Choose from:
{0 = Use the default iterative solver ( TDMA ),
1 = Use the CGSQ solver on the U momentum
equation,
2 = Use the CGSQ solver on the V momentum
equation,
4 = Use the CGSQ solver on the W momentum
equation,
16 = Use the CGSQ solver on the energy equation,
64 = Use the CGSQ solver on the turbulence intensity
equation,
128 = Use the CGSQ solver on the turbulence
dissipation equation, or
512 = Use the CGSQ solver on the density equation for
compressible flow}
The default is 0.
CONVTOL--specifies the convergence tolerance which will be used in

conjunction with the default non-symmetric iterative solver.
Enter a floating (real) value. The default is 1.0000e-04.

RUN PARAMETERS
DIAG--specifies the diagonal preconditioning flag for the symmetric

solver.
Choose from:
{0 = use partial Cholesky preconditioning for
everything,
8 = use diagonal preconditioning for pressure,
16 = use diagonal preconditioning for energy, and
16384 = use diagonal preconditioning for radiosity}
The default is 16384.
DT--specifies the initial time step size. Setting DT to zero when INILEV
> 0 will cause ProCAST to use the DT at step INILEV.

Select the units of time from: {sec | min}
DTMAX--specifies the maximum time step size.
Enter a floating (real) value. The default is 5.0000e+00.

INILEV--specifies the initial time level. When an analysis is first

started, INILEV should be equal to zero. When you are
resuming an analysis, INILEV should be set to the time step
from which you would like to continue. Note: You must have
results for that time step.
Enter an integer value. The default is 0.
LUFAC--specifies the preconditioning parameter for the CGSQ solver.

This parameter may speed-up a large model(500,000+
elements, 100,000+ nodes) solution
Choose from:
{0 to use diagonal preconditioning, or
1 to use partial LU factorization preconditioning}
The default is 1.
NCYCLE--specifies the number of casting cycles to be simulated in a

continuous mode. This parameter is used along with TCYCLE.
Both NCYCLE and TCYCLE must be set. This parameter is
typically used in die casting, permanent mold problems.

RUN PARAMETERS
NEWTONR--turns on the NEWTON Raphson technique for the energy

equation.
Choose from:
{0 to turn off the Newton Raphson technique,
1 to turn the Newton Raphson technique on, or
2 to turn on the Newton Raphson technique and use b-
splines}
The default is 0.
Option 2 results in using b-splines instead of linear line

segments in the representation of the thermal
properties. It is suggested that all thermal input data be
smoothed before attempting to use b-splines.
NPRFR--specifies the printout frequency. This controls the time step

interval at which results are output to the prefixp.out file.
NRSTAR--specifies the number of allowable restarts before the entire

run is abandoned. A restart occurs when the maximum number
of corrections is reached. If too many restarts are taking place,
it could indicate problems with the model setup.
NSTEP--specifies the number of time steps to take in the current run

and is used in conjunction with TFINAL. ProCAST will
terminate the run when it reaches this limit or the TFINAL
value, whichever occurs first.

RUN PARAMETERS
PRNLEV--specifies the level of nodal results to be printed out. The

values specified in this parameter may be added together. This
allows you to collect combinations of nodal information in a
single run.
Choose from:
{0 = no printout,
1 = nodal velocities,
8 = nodal pressures,
16 = nodal temperatures,
64 = nodal turbulence intensities,
128 = nodal turbulence dissipation rates,
1024 = nodal displacements,
8192 = surface heat fluxes, and
32768 = nodal magnetic potentials}
The default is 0.
SDEBUG--specifies the level of solution debugging messages to be

captured. These messages are written to the p.out file.
Choose from:
{0 to capture no solution debugging messages, or
1 to obtain information concerning, solver performance,
time step control, and the free surface model}
The default is 1.
TCYCLE--specifies the time of casting cycle to be simulated in a

continuous mode. This parameter is used along with NCYCLE.
Both NCYCLE and TCYCLE must be set.

TFINAL--specifies the simulated time at which to terminate a ProCAST

analysis. If this parameter is zero, the run will be stopped by
the NSTEP parameter. If both the NSTEP and TFINAL
parameters are set, the simulation will be terminated based
upon which parameter is reached first.

TMODR--specifies the time step modification factor for restarts. If

MAXCOR correction steps are taken without convergence, the
time step is multiplied by TMODR. Therefore, this number
should be less than 1.

RUN PARAMETERS
TMODS--specifies the time step modification factor for normal

stepping. If the number of correction steps is less than or equal
to NCORL, the subsequent time step is multiplied by TMODS.
If the number of correction steps is greater than or equal to
NCORU, the subsequent time step is divided by TMODS.
USER--this parameter is used to trigger user specific routines. These

parameters are provided as hooks into ProCAST. Contact
ProCAST Technical Support to discuss the applicability of this
parameter for your use.
When you are satisfied with the parameters and their values, click on
the APPLY push button. This will store the values you have entered in
the prefixp.dat file.
You may close this display without saving the parameters you entered
or changes you may have made by clicking the CANCEL push button.
Remarks Changing from the TEMA solver to the CGSQ solver may improve the
solve time in larger (500,000+ elements, 100,000+ nodes) models.
Related Topics

RUN PARAMETERS
RUN PARAMETERS
THERMAL
Description THERMAL is a push button in the RUN PARAMETERS menu. It

provides the capability to specify the options used in thermal analyses.
Method THERMAL is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the thermal
parameters and, if applicable, units associated with a parameter.
The figure shown above illustrates the THERMAL dialog box. The
THERMAL parameters and the available options for each parameter
will be discussed here. For convenience in presentation, they will be
CLUMP--specifies the capacitance matrix lumping factor.
Enter:
{0 to use consistent matrix, or
1 to use diagonal matrix}
The default is 1.
CONVT--specifies the convergence criterion for temperature. A value

of around one degree is generally appropriate. Values larger
than the mushy (liquidus--solidus) zone range are not
recommended.

Select the units of temperature from: {C | F | R | K}
CRELAX--specifies the heat capacity relaxation parameter.

RUN PARAMETERS
LINSRC--specifies the source term linearization parameter for

micromodels. This parameter may be used in conjunction with
micromodels that control the evolution of the solid fraction and
thus the release of latent heat. The default value of zero
indicates that the heat generation will only appear in the right
hand side source term. A value of one will give some
contribution to the diagonal terms of the left hand side matrix.
This improves numerical stability, but does require that the LHS
be factored, which would normally happen anyway.
Enter:
{0 = no linearization, or
1 = for linearization of the source term}
The default is 0.
MFREQ--specifies the time step interval for writing micromodel results

to the unformatted file. This parameter can be used to reduce
the size of the micro results file, which can become quite large
for problems with may nodes and time steps. Note that it is
only possible to restart a run from one of the time steps that
was written out.
MICRO--specifies the micromodeling to be performed. The values

specified in this parameter may be added together. This allows
you to use a combination of micromodeling models in a single
run.
Enter an integer value based upon the following:
{0 = no micromodeling,
1 = Eutectic ductile iron,
2 = Equiaxed dendrite,
4 = Stable/metastable eutectic with instantaneous
nucleation,
8 = Stable/metastable eutectic with continuous
nucleation,
16 = Eutectic gray/white iron,
32 = Eutectoid ductile iron,
64 = Eutectoid gray iron,
128 = Peritectic transformation,
256 = Delta/gamma, gamma/alpha, and
gamma/cementite transformations,
512 = Scheil model for primary solidification, or
1024 = Solid Transformations}
The default is 0.

RUN PARAMETERS
MOBILE--specifies the Mobility factor. This parameter is the critical

liquid fraction at which the free surface losses its mobility.
Values between zero and one are acceptable. Piping depth can
be quite sensitive to this parameter.
POROS--specifies the porosity calculations to be performed.
Choose from:
{0 for no porosity calculation,
1 to compute macro porosity, or
2 to compute porosity effects associated with a
dissolved gas}
The default is 1.
QFREQ--specifies the time step interval for writing heat flux data to the
unformatted results file. This parameter can be used to reduce
the size of the prefixq.unf file. Heat flux results may not be of
interest to everyone, so it may be desirable to minimize the size
of this file.
TFREQ--specifies the time step interval for writing temperature data to

the unformatted results file. This parameter can be used to
reduce the size of the prefixt.unf file, which can become quite
large for problems with many nodes and time steps. Note that
it is only possible to restart a run from one of the time steps that
was written out.
THERMAL--specifies the thermal analysis to be performed.
Choose from:
{0 for no thermal analysis. Solve flow equations alone,
1 to perform thermal analysis, using temperature as the
primary variable, or
2 to perform thermal analysis, using enthalpy as the
primary variable}
The default is 1.

RUN PARAMETERS
TRELAX--specifies the temperature relaxation parameter. This is used

for computing the initial guess for the temperature field in the
predictor step. TRELAX should be greater than or equal to zero
and less than or equal to one.
When you are satisfied with the parameters values, click on the APPLY
push button. This will store the values you have entered in the
prefixp.dat file.
Remarks The THERMAL parameters apply to every simulation wherein the

energy equation is being solved.
Related Topics RUN PARAMETERS

RUN PARAMETERS
RUN PARAMETERS
RADIATION
Description RADIATION is a push button in the RUN PARAMETERS menu. It

provides the capability to specify radiation parameters and tolerances to
be applied during the simulation.
Method RADIATION is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the radiation
parameters and, if applicable, units associated with a parameter.
The figure shown above illustrates the RADIATION dialog box. The
RADIATION parameters and the available options for each parameter
will be discussed here. For convenience in presentation, they will be
ANGTOL--specifies the angle tolerance to be used with VFLIM.

Radiation faces which are grouped using VFLIM tolerance are
further differentiated by their solid angle.
ENCLID--specifies an enclosure identification number. This parameter

is used in combination with VFDISP for updating view factors
by a displacement interval. ENCLID indicates which enclosure
set is to be tracked, in case all the enclosure elements are not
moving at the same rate.
EPTOL--specifies the emissive power tolerance to be used with VFLIM.

Radiation faces which are grouped using VFLIM tolerance are
further differentiated by their solid angle.

RUN PARAMETERS
RDEBUG--specifies the user debug parameter for printing detailed view

factor information. Various combinations of these files may be
obtained by adding together these numbers. For example,
RDEBUG = 7 gives all three files. Note that these files can be
quite large, especially the prefix.vf.
Enter an integer value based upon the following:

{1 for face to face view factors after symmetrization, in
the prefix.vf file,
2 for face to group view factors after symmetrization, in
the prepfix.view file (necessary to see FACE TO
GROUP in ViewCAST), or
4 for row sum errors before symmetrization, in the
prefix.serr file (necessary to see ROW SUM ERRORS
in ViewCAST}
The default is 0.
RFREQ--specifies the radiation update frequency. This provides a

mechanism for recomputing the radiosities at some time step
interval other than one. This is particularly useful if you are
performing a filling transient along with the view factor radiation
model. In this case, the time step size may be small due to the
filing whereas the mold temperature may not be changing very
rapidly. You can save some computational time by
recomputing the radiosities at every tenth step, for example.
VFDISP--specifies the displacement interval for updating view factors

in the radiation model if there are moving relative surfaces.
This is used in conjunction with ENCLID and will be used in
preference to VFTIME if both are specified.

Choose the units of length from: {m | cm | mm | ft | in}. The
default is m.

RUN PARAMETERS
VFLIM--specifies the view factor limit. This parameter is used to

agglomerate faces in the view factor calculations. This reduces
the size of the radiosity matrix and speeds up the radiation
calculations.
VFLIM can be set to a fraction between zero and one. If one

face occupies less than this fraction of the total view space, as
seen from another face, the first face is combined with some
others. A value of 0.01 is a good starting point.
VFTIME--specifies the time interval for updating view factors in the

radiation model if there are moving relative surfaces.

Choose the units of time from: {sec | min}. The default is sec.
Remarks The RADIATION parameters come into play when the view factor
radiation model is employed.

RUN PARAMETERS
RUN PARAMETERS
FLOW
Description FLOW is a push button in the RUN PARAMETERS menu. It provides
the capability to specify the flow solutions to be performed and the flow
tolerances to be used during simulation.
Method FLOW is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the flow parameters
and, if applicable, units associated with a parameter.
The figure shown above illustrates the FLOW dialog box. The FLOW
parameters and the available options for each parameter will be
discussed here. For convenience in presentation, they will be
ADVECTW--specifies the weighting of advection velocities and controls

the degree of non-linearity of the momentum equations.
ADVECTW can take on values between zero and one.

Velocities at the last time step are used as the advecting
velocities if a value of zero is used. Velocities at the current
time step are used as the advecting velocities if a value of one
is used.
Numerical experience has shown that the accuracy of natural

circulation flows can be enhanced by using a factor of 0.5. For
most filling analyses, a value of zero works fine and requires
much less computational time.

RUN PARAMETERS
COARSEC--specifies the constant coefficient for the coarsening

equation.
COARSEP--specifies the power coefficient for the coarsening equation.
COMPRES--specifies whether this is an incompressible flow problem or

a compressible flow problem.
Choose from:
{0 to specify an incompressible flow problem, or
1 to specify a compressible flow problem}
The default is 0.
CONVV--specifies the convergence criterion for velocity. The value

given here is a fraction of the maximum velocity calculated at
each step. Generally, .05 or 5% is appropriate.
COUPLED--specifies whether the energy and fluid solutions should be

coupled or decoupled within a time step.
When the analysis is decoupled, the momentum and pressure

equations are solved repeatedly until convergence.
Subsequently, the energy equation is solved until convergence,
assuming the flow field is fixed. With a coupled analysis, the
energy equation is solved in the same loop with momentum
and pressure. Both the momentum and temperature
convergence criteria have to be met to terminate the loop. This
method is more accurate, but usually takes more computational
time.
Choose from:
{0 to decouple energy and fluid solutions withing a time
step, or
1 to fully couple energy and fluid solutions within a time
step}
The default is 0.

RUN PARAMETERS
COURANT--specifies the courant limit on time step size. This

parameter is only used for fluids problems. If COURANT is set
to 1.0, the time step will be adjusted so that the fluid will
advance no more than one element length. This is a fairly
severe limit on time step size, but will give the most accurate
results for filling transients. Acceptable results can usually be
obtained with values between 10 and 50. For compressible
flow problems, a COURANT limit of 0.5 is suggested.
EDGE--controls the algorithm for advecting the free surface front along
the wall. Using the tangent component helps the flow to go
around corners when the mesh is relatively coarse, but
sometimes causes the fluid to flow preferentially along walls.
Using the nearest free stream nodal velocity provides a

mechanism for detaching the flow from the wall. If flow
detachments are expected, then the nearest free stream nodal
velocity option should be used.
Choose from:
{0 = use the tangent component of the nearest free
stream nodal velocity, or
1 = use the nearest free stream nodal velocity}
The default is 0.
FFREQ--specifies the flow update frequency. This provides a

mechanism for re-computing the velocities at some time step
interval other than one. This might come into play if you were
solving a conjugate heat transfer problem where the velocity
field is changing on a longer time scale than the temperatures.
This option is not appropriate for free surface problems.

RUN PARAMETERS
FLOW--controls the use of fluid equations.

Choose from:
{0 do not solve fluid equations,
1 to solve fluid equations,
3 to solve fluid equations during filling, but switch over
to thermal only analysis when the LVSURF fill limit is
reached and NCYCLE = 1,
5 to calculate the potential flow analysis using the
boundary element method,
9 to solve fluid equations during filling, but switch over
to thermal only analysis when the LVSURF fill limit is
reached and NCYCLE > 1}
The default is 0 if there are no F materials. If F
materials exist, the default is 1.
FLOWDEL--specifies the delay time between the end of fill and a

switch to a thermal only, FLOW = 3 simulation. This option is
used in conjunction with velocity boundary conditions with
active fill limits. The time delay buys time for the fluid to
completely settle down in the casting before the thermal only
phase begins.

Select the units of time from: {sec | min} The default is sec.
FREESF--specifies the free surface model number to be used.
Choose from:
{1 = use the momentum dominated movement of free
surface, rapid filling model,
2 = use the gravity dominated movement of free
surface, slow filling model, or
3 = hybrid model, switch between 1 and 2 depending
upon conditions}
The default is 0.

RUN PARAMETERS
GAS--specifies whether or not to consider the trapped gas effects. If

the option to consider trapped gas effects is chosen, trapped
gas effects will be considered even when the model contains no
vents, gas injection, or gas diffusion through the mold. When
features normally found in a gas problem ( vents, injection, or
gas diffusion through the mold ) are present in a model, GAS
will be set automatically.
Choose from:
{0 to not consider trapped gas effects, or
1 to consider trapped gas effects}
The default is 0.
HEAD_ON--specifies the approach to be used when calculating

gravitational term in the momentum equation for flow problems
without free surfaces.
Choose from:
{0 = calculate as rho - rho_ref, or
1 = calculate as rho * g}
The default is 0.
HIVISC--specifies different solution methods for viscosity in the flow

problem.
Choose from:
{0 = normal flow problem,
1= high viscous flow problem. To be used when the
Reynolds number is less the one. This method only
works for viscosity less than 104 poise. In this case, the
advection terms are neglected, symmetric solvers are
employed on the momentum equations, and large
degrees of pressure relaxation are utilized, or
2 = very high viscous flow problem. To be used when
the Reynolds number is less the one. This method is
always preferred. In this case, the advection terms are
neglected and momentum effect on implicitly included
within a Poisson pressure equation. This option usually
allows for much larger time steps than HIVISC = 1}
The default is 0.

RUN PARAMETERS
LVSURF--provides a way to switch from the filling transient to a mode

where advection is due to buoyancy and shrinkage. LVSURF
turns all inlets off. It is assumed thereafter that the free surface
is perpendicular to the gravity vector. This allows the time step
to increase significantly.
The number represents the fraction of the total casting and
rigging volume which is to be filled before changing modes.
MLUMP--specifies the mass matrix lumping factor.
Choose from:
{0.0 to use a consistent matrix, or
1.0 to use a diagonal matrix}
The default is 1.00000e+00.
NNEWTON--specifies whether the flow is newtonian or non-newtonian.
Choose from:
{0 to indicate Newtonian flow, or
1 to indicate non-newtonian flow, where viscosity is a
function of shear rate}
The default is 0.
PINLET--specifies a pressure drive inflow. Setting PINLET to 1

indicates that all the pressure boundary conditions are also
inflow boundary conditions. Use of this option allows one to
avoid using thin filled regions at the inlets of pressure driven
problems. It allows for filling of metal without having an initial
layer of fluid.
Enter an integer value of 0 (off) or 1 (on). The default is 0.
PLIMIT--specifies the pressure cutoff limit. You can use this parameter
to turn off an inlet velocity when the back pressure exceeds the
given value. This is useful particularly in cases where cold
shuts are occurring. Otherwise, the program will keep trying to
force more mass into the fluid region, even though there is no
place for it to go, and the pressure will continue to rise.

Choose the pressure units from: {N/m**2 | Pa | KPa |
The default is N/m**2.

RUN PARAMETERS
PREF--specifies the pressure which is to be subtracted from any

boundary condition pressure in order to convert an absolute
pressure into a gauge pressure. This parameter comes into
play when: (1) there is trapped gas, (2) a pressure boundary
condition drives the flow, (3) there are vents, and/or (4) there is
gas injected. For example, if the pressure boundary condition
drives the flow at a gauge of 1 atmosphere, the boundary
condition is set to 2 atm. PREF should be set to 1 atm.

Choose the pressure units from: {N/m**2 | Pa | KPa |
The default is N/m**2.
PRELAX--specifies the pressure relaxation factor. PRELAX, to have an

effect, should be greater than zero and less than one. If it is
left to the default value of one, ProCAST will automatically
compute an appropriate relaxation factor.
SPLIT--This parameter is obsolete.
TPROF--This parameter indicates that a thermal boundary layer profile

is used at the wall for the energy equation with advection. This
has been found to reduce false diffusion errors.
Choose from:
{0 = do not use boundary layer profile, or
1 = use boundary layer profile}
TSOFF--This parameter specifies the time at which to switch off the

flow solution. For example, TSOFF 1 42, indicates that the
flow solution will be turned off 42 seconds into the simulation.
If a cyclic analysis is being performed, then the flow solution
will be turned off 42 seconds into each cycle.
Choose from:
{0 = turns this option off, or
a real value sets the time}

Choose the time units from: {sec | min}. The default is
sec.
VFREQ--specifies the time step interval for writing velocity and

RUN PARAMETERS
pressure results to the unformatted files. This parameter can

be used to reduce the size of these results files, which can
become quite large for problems with many nodes and time
steps. Note that it is only possible to restart a run from one of
the time steps that was written. Only the steps that are written
can be viewed with post-processing.
WSHEAR--specifies whether or not the wall shear formulation will be

used. The wall shear formulation will convert no-slip boundary
conditions into wall traction conditions.
Choose from:
{0 to indicate that wall shear formulation will not be
used, or
1 to indicate wall shear formulation will be used}
The default is 0.
Remarks The FLOW parameters allow you to specify the type of fluids analysis
to be performed. They also allow you to make adjustments to control
some trade-off between speed and accuracy.

RUN PARAMETERS
RUN PARAMETERS
TURBULENCE
Description TURBULENCE is a push button in the RUN PARAMETERS menu. It

provides the capability to specify turbulence parameters to be applied
during the simulation.
Method TURBULENCE is activated by clicking on it. This results in the

immediate action to display a dialog box containing a list of the
turbulence parameters.
The figure shown above illustrates the TURBULENCE dialog box. The
TURBULENCE parameters and the available options for each
parameter will be discussed here. For convenience in presentation,
CMU--specifies the proportionality constant used in the turbulent

viscosity equation. See Equation C.6.1 in Appendix C.
CONE--specifies the proportionality constant used in the production of

turbulent energy dissipation. See Equation C.5.1 in Appendix
C.
CTWO--specifies the proportionality constant used in the destruction of

turbulent energy dissipation. See Equation C.5.1 in Appendix
C.
KAPPA--specifies the Von Karmans constant, usually taken as 0.4

RUN PARAMETERS
SIGMAE--specifies the diffusivity modifier used in the turbulent energy

dissipation transport equation. See Equation C.5.1 in Appendix
C.
SIGMAK--specifies the diffusivity modifier used in the turbulent kinetic

energy transport equation. See Equation C.4.1 in Appendix C.
TBRELAX--specifies the turbulence relaxation parameter.
TURB--specifies whether the turbulent flow model is turned on or off. A

model started with TURB = 1 can be restarted at a later time
with TURB = 0. This allows laminar conditions to be considered
during mushy or natural circulation flows.
Once TURB has been set to zero, the turbulence model can not
be restarted at a later time. Setting TURB to one for a flow
problem which has no turbulence boundary conditions assigned
is okay; ProCAST will automatically define them.
Enter:
{0 to turn the turbulent flow model off, or
1 to turn the turbulent flow model on}
The default is 0.
Remarks The default TURBULENCE parameters are used in the standard ---
model, but they are all adjustable.

RUN PARAMETERS
RUN PARAMETERS
STRESS
Description STRESS is a push button in the RUN PARAMETERS menu. It

provides the capability to specify stress parameters and tolerances to
Method STRESS is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the stress parameters
and, if applicable, options associated with a parameter.
The figure shown above illustrates the STRESS dialog box. The
STRESS parameters and the available options for each parameter will
be discussed here. For convenience in presentation, they will be
CONVS--specifies the convergence criterion for the stress calculation.
SFREQ--specifies the time step interval for writing stress results to the
unformatted files. This parameter can be used to reduce the
size of these files, which can become quite large for problems
with many nodes and time steps. Note that it is only possible to
restart a run from one of the time steps that was written. This
also controls the frequency for performing stress analysis.

RUN PARAMETERS
STRESS--specifies whether the stress calculation is turned on or off.

Enter:
{0 to turn the stress calculation off, or
1 to turn the stress calculation on}
The default is 0.
Remarks The default STRESS parameters are those normally used in most
stress models, but they are all adjustable.

RUN PARAMETERS
RUN PARAMETERS
ELECTROMAGNETIC
Description ELECTROMAGNETIC is a push button in the RUN PARAMETERS

menu. It provides the capability to specify electromagnetic parameters
to be applied during the simulation.
Method ELECTROMAGNETIC is activated by clicking on it. This results in the

immediate action to display a dialog box containing a list of the
electromagnetic parameters and, if applicable, options associated with
a parameter.
The figure shown above illustrates the ELECTROMAGNETIC dialog

box. The ELECTROMAGNETIC parameters and the available options
for each parameter will be discussed here. For convenience in
presentation, they will be presented in alphabetical order.
CFREQ--specifies the driving frequency ( hertz ) of the current which

flows inside the induction coil.
EFREQ--specifies the time step interval for writing electromagnetic

results to the unformatted files. This parameter can be used to
reduce the size of these files, which can become quite large for
problems with many nodes and time steps. Note that it is only
possible to restart a run from one of the time steps that was
written out.
EM--specifies whether the electromagnetic calculation is turned on or

off.
Enter:
{0 to turn the electromagnetic calculation off, or
1 to turn the electromagnetic calculation on}
The default is 0.

RUN PARAMETERS
EMITER--specifies the number of solver iterations allowed when

solving the magnetic potential equations.
Remarks To run electromagnetics EM must be set to 1 and CFREQ has to be

given a realistic value.

RUN PARAMETERS
RUN PARAMETERS
INVERSE
Description INVERSE is a push button in the RUN PARAMETERS menu. It

provides the capability to specify inverse parameters and tolerances to
Method INVERSE is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the inverse
parameters.
The figure shown above illustrates the INVERSE dialog box. The
INVERSE parameters and the available options for each parameter will
be discussed here. For convenience in presentation, they will be
CONV--specifies the convergence tolerance. The convergence will be

reached when the variation, between two iterations, of each
property will be smaller than this value.
ITERMAX--specifies the maximum number of iterations before the

calculation is terminated. In some cases, if the tolerance is too
small, the variation of the beta values will not be within the
tolerance, although the calculation would have converged. A
value between 15 and 30 iterations is reasonable.
SIGMA--specifies the weighting coefficient for temperature. The

weighting coefficient for temperature should be kept small in
order to have good convergence. A value of 0.1( C has proven
to give good results.

RUN PARAMETERS
TAU--specifies the time constant for the filtering of measurements. In

order to remove small perturbations which might occur during
the measurements, the curves are filtered using the time
constant. The units of TAU are seconds.
Enter a floating (real) value. The default is 1.0000e+00
VARB--specifies the variation of each beta value during an iteration.

During an iteration, the beta values will be perturbed one after
the other in order to determine the sensitivity coefficients of
each property. To do so, each beta value will be changed by a
given amount corresponding to the value of varb times the beta
value. Values of varb between 0.05 and 0.2 are convenient
and correspond to a variation of 5 to 20% of the beta values.
Remarks A display window is displayed in which you must enter the node
numbers or node coordinates which correspond to the location of the
measurement points. The order of this list should correspond to the
order of the measured curves in the measurement file, prefixim.dat.
The proper sequencing of these lists is mandatory because the
calculated and measured curves will be compared in the inverse
calculation and should correspond to the identical location.

RUN PARAMETERS
RUN PARAMETERS
CAFE
Description CAFE is a push button in the RUN PARAMETERS menu. It provides

the capability to specify parameters and tolerances to be applied to the
CAFE model during the
simulation.
Editors Note: The CAFE capability has not yet been implemented in ProCAST.
Method CAFE is activated by clicking on it. This results in the immediate action
to display a dialog box containing a list of the CAFE parameters and, if
applicable, units associated with a parameter.
The figure shown above illustrates the CAFE dialog box. The CAFE
parameters and the available options for each parameter will be
discussed here. For convenience in presentation, they will be
CELLSZ--is the length dimension for the cellular automata cells.

Select the units of measure from: {m | cm | mm | ft | in}. The
default is m.
ISEED--is the initialization parameter for random number generation.
the prefixp.dat file. You may close this display without saving the
parameters you entered or changes you may have made by clicking the
CANCEL push button.
Remarks None.

USING DATACAST
CHAPTER 4
USING DataCAST
Description DataCAST reviews the total model, performs extensive error checking,
and converts all the units into standard CGS. DataCAST also creates a
summary file which describes the complete analysis model. This
summary file provides one form of model documentation.
When DataCAST has completed its error checking, it creates the binary
files which will be read by ProCAST as the simulation input.
Method DataCAST runs in a either a Unix or a Microsoft Windows NT session

window.
DataCAST can be started using the following command line instruction

at the session window prompt or the Run Dialog Window:
datacast {prefix} [-u | -v | -d ] ENTER
DataCAST may also be started from the EXECUTE menu in the PCS
screen.
-u is an update option. This recreates the model files without re-

initializing the results.
-v is a command line option which specifies verbose output in the error
messages. By default, nodes and elements are no longer
printed in error messages.
-d is a command line option which specifies that the determinant of the
Jacobian should be checked. This identifies bad elements.
Remarks If you start a DataCAST session without the prefix parameter shown
above, you will be given a message in the session window and
prompted to enter a prefix.
The formatted file containing the description of the problem is the

prefixd.dat file. This is the file which is read by DataCAST. The
complete file format and record description for this file may be found in
Appendix D.
USING DATACAST, PAGE 4 - 1

USING DATACAST
If DataCAST encounters any errors in the model, it will display

appropriate messages on the workstation screen. These error
messages are also written into the formatted file prefixd.out. When
DataCAST has completed its processing, the formatted file prefixd.out
will be available for viewing. This file contains a log of all the
geometry, material properties, and boundary/initial conditions converted
into CGS units, and any error messages. Temperatures are in units of
degrees Kelvin. If errors do occur, they should be corrected before
going on to run ProCAST.
Related Topics prefixd.dat File Format (Appendix D)

USING PROCAST
CHAPTER 5
USING ProCAST
Description ProCAST performs the simulation analysis.
Method ProCAST runs in a either a Unix or a Microsoft Windows NT session

window.
ProCAST can be started, on the Unix platform, using the following

command line instruction at the session window:
procast {prefix} [ & ] ENTER
ProCAST can be started, on the NT platform, using the following

command line instruction at the session window prompt or the Run
Dialog Window:
prosolve {prefix} [ & ] ENTER
ProCAST may also be started from the EXECUTE menu in the PCS
screen.
& is a command line option which specifies that ProCAST will be run in
the batch or background mode.
Remarks If you start ProCAST without the prefix parameter shown above, you
will be given a message in the session window and prompted to enter a
prefix.
ProCAST can be run either in the foreground or in batch mode. Since

the main number crunching occurs in ProCAST, these runs are
relatively long and batch mode is usually preferable.
When the run has finished, the results will be contained in a variety of
files. These files are described in Appendix B: ProCAST File Usage.
The prefix.out file contains useful information about the run such as the
memory usage, the convergence behaviour, the iterations and cpu
times taken by the solvers, etc. This can be helpful in identifying
problems in an analysis.
You can view the formatted file prefixp.out, which can have nodal
values of temperature, pressure, velocity and heat flux. The various
unformatted results files that have the unf extension are read by
PostCAST and ViewCAST for postprocessing.
There is a small utility program which can be run to report the status of
USING PROCAST, PAGE 5 - 1

USING PROCAST
any ProCAST analysis which is currently running or which has

completed its processing. This utility may be started by opening a Unix
session window and typing the following command at the session
window prompt:
prostat {prefix} ENTER
ProSTAT will provide information about the simulation which includes:

number of time steps completed, total simulated time, current time step
size, percent filled, solid fraction, cycle number, elapsed CPU time, and
elapsed wall clock time for the job prefix. An example of a ProSTAT
Report is shown here.
NUMBER OF STEPS = 10
SIMULATED TIME = 1.023000 SECONDS
TIME STEP = 0.512000 SECONDS
PERCENT FILLED = 100.000000 %
SOLID FRACTION = 0.000000 %
CYCLE 1 IS 0.000000 % COMPLETE
CUP TIME = 0.070000 SECONDS
SYSTEM TIME = 0.080000 SECONDS
WALL CLOCK TIME = 1 SECONDS
STEP COMPLETED ON Dec 18 1996 AT 17:30:03
Related Topics ProCAST File Usage (Appendix B)

USING POSTCAST
CHAPTER 6
USING PostCAST
Description PostCAST provides the post-simulation capability to extract data from

the simulation results data files and format it for further analysis.
PostCAST provides the capability to graphically display temperature,
velocity, pressure, fraction solid, and stress versus time results.
PostCAST files may be displayed graphically using ViewCAST,
PATRAN, or IDEAS.
Method PostCAST runs in a either a Unix or a Microsoft Windows NT session

window.
PostCAST can be started using the following command line instruction

postcast {prefix} [ -f filename ] ENTER
PostCAST may also be started from the EXECUTE menu in the PCS
screen.
-f filename is a command line option for batch processing instructions.

The filename specifies the file containing the instructions. This
option currently will do just a subset of the total capabilities of
PostCAST.
Remarks If you start a PostCAST session without the prefix parameter shown
above, you will be given a in the session window and prompted to enter
a prefix.
When PostCAST is activated, it will display a work space with a gray

(by default) background, the UES logo in the lower right-hand corner,
and a Main Function Banner across the top of the work space. You
may use the push buttons in this banner to navigate through the
functions of PostCAST.
These functions are:

OPTIONS, FORMAT, STEPS,
UNITS, MATERIALS, and EXIT
right placement in the Function Banner.
USING POSTCAST, PAGE 6 - 1

USING POSTCAST
The following information can be provided by PostCAST.

Temperature results at each stored time step,
Pressure results at each stored time step,
Velocity results at each stored time step,
Turbulence quantities at each stored time step,
Heat flux results at each time stored step,
Time to reach a given temperature (Isochrons),
Temperature, fraction solid, pressure, velocity, and stress versus
time results for various nodes,
Solidification rate, cooling rate, and temperature gradient results
which can be combined into a factor indicative of microscopic
features,
Niyama or LCC criteria,
R, G, L criteria,
SDAS,
Alpha case,
Feeding length at the end of solidification, and
Row sum errors from the radiation model.
Related Topics OPTIONS, FORMAT, STEPS, UNITS, MATERIALS, EXIT

OPTIONS
OPTIONS
Description OPTIONS is a push button in the Main Function Banner. This function
of PostCAST enables you to select options to be applied during the post
processing functions. These options will influence the manipulation of
results obtained from the ProCAST simulations and solutions. When
you activate the OPTIONS push button, a menu is opened which will
allow you to work with specific aspects of the simulation results. The
functions available from this menu will be discussed in this section.
Method OPTIONS is activated by clicking on it. The initial menu is shown here.
When you select a function from this
menu, PostCAST will display additional
Dialog Boxes, Option Lists, Data Input
Windows, or sub-menus. These
graphical interface tools will guide you
through the process of specifying,
the options and their alternative
attributes.
You may leave the OPTIONS function by

clicking another push button in the Main
Function Banner.
Remarks The OPTIONS function of PostCAST

provides the capability to select portions
of the results of the simulation for further
analysis, examination or processing. For
example, this selection process allows
you to select thermal or velocity results for every tenth node, every
other node or every 50th node for viewing and analysis. The PostCAST
options will influence the manipulation of results obtained from the
ProCAST simulations and solutions.
Other functions available from the PostCAST Main Function Banner,

such as MATERIALS or STEPS, may affect the parameters you specify
with these OPTION parameters. For example, if you are interested in
looking at only one material, you should designate that material using
the MATERIALS push button in the Main Function Banner before
specifying OPTIONS. Similarly, if you are interested in examining the
results from one time step, you should designate that time step using
the STEPS push button in the Main Function Banner before specifying
OPTIONS.
Related Topics

OPTIONS
OPTIONS
X-Y PLOT
Description X-Y PLOT is a push button in the OPTIONS menu. It provides the
capability to plot the Temperature, Fraction Solid, Pressure, Velocity,
and Stress and Strain versus time results of the simulation. You may
select or specify the nodes to be displayed in the plots. Using the
OPTIONS menu, X-Y PLOT also provides the capability to customize,
to an extent, the appearance of the resulting plots.
Method X-Y PLOT is activated by clicking on it.

display a sub-menu of push buttons
which list the types of plots for which
nodal selections may be made. The
figure shown here illustrates this sub-
menu.
When you select an option from this

menu, the background of that push
button is highlighted in red and an
additional sub-menu will be displayed.
This sub-menu provides the capability to
specify the method by which nodes are to be selected for the
Temperature, Fraction Solid, Pressure, Velocity, and Stress plotting.
Graphically, the sub-menu for

specifying the nodal values is
the same when you choose
any option except
temperature. When you
choose TEMPERATURE, the
sub-menu includes the
EXTERNAL option. The
example shown here
illustrates this sub-menu
display after choosing the
Temperature option. Notice
that the TEMPERATURE
push button has been highlighted.
Each of these nodal selection push button options, Interval, Nodes,

Options, and External, will be discussed in this section. For
convenience they will be presented in alphabetical order.

OPTIONS
You may close this display and move to another function of PostCAST
or to another function of OPTIONS by clicking the appropriate Main
Function Banner or Menu push button respectively.
EXTERNAL
PostCAST allows you to read temperature - time data from other
sources, such as thermocouples, to plot on the same picture as the
simulation results. The EXTERNAL push button allows you to specify
the file names containing this external data.
When you click on the

EXTERNAL push button in
the sub-menu, PostCAST
displays the file input display
as shown in the figure here.
Entering data in the table is

done by first selecting the
desired table entry. You
select a table entry by
clicking on the desired entry.
If the table is empty, select
the area in the first row. This
is illustrated in the figure
shown here.
Once a table entry is selected

the background of that entry
will change to red and the cursor will be placed in the Enter File Name
input box. If the entry contains data, the data will be displayed in the
Enter File Name input box. You may then enter or change the file
name in the input box.
You may enter up to ten different file names. If the file is not in the
current directory, then you need to provide the full path name and file
name. When you are satisfied with the new data, press ENTER. This
will place the value in the highlighted table entry and move the cursor to
the next available table entry.
External File contents and format--the first row of an external file should
contain the number of thermocouples or temperature values given at
each time. This should be followed by the thermocouple identification
numbers which will be used to label the curves in the temperature plot.
Subsequent rows in the file should have a time value and temperature
for each thermocouple. All data is read in free format and should be
separated by a space between each value.
You may have as many thermocouple results as you can fit on one line.

OPTIONS
Up to 5000 time levels may be given in one file.
INTERVAL
PostCAST allows you to specify a node number interval for plotting.
For example, if you wanted to see the cooling curve for every tenth
node, you would enter an interval of 10. The default is one, or every
node.
The INTERVAL option is very useful for a quick look at the thermal
results of the simulation. It can tell you if the simulation is behaving
properly or if the results are becoming erratic, which may indicate an
error in the problems setup.
When you click on the INTERVAL

push button in the sub-menu,
PostCAST displays an Edit Value
input box as shown in the figure here.
To enter an interval value, place the

cursor in the Edit Value input line, type the desired integer value, and
click on the APPLY push button.
You may close this display without specifying or changing the interval
value by clicking the CANCEL push button.

OPTIONS
The example shown here is an X-Y Plot of the temperature of a casting

where the temperature of every 100th node was selected using the
INTERVAL option.
NODES
PostCAST allows you to specify node numbers for plotting. When you
click on the NODES push button in
the sub-menu, PostCAST displays
the Nodal Values input display as
shown the figure here.
Entering data in the table is done by

first selecting the desired table entry.
You select a table entry by clicking on
the desired entry. If the table is
empty, select the area in the first row.
This is illustrated in the figure shown
here.
If the table contains nodal values and

you want to add another value, use
the scroll bar, if necessary, to move
to the end of the table and select the
first empty area.
Once a table entry is selected the background of that entry will change
Box. You may then enter or change the node number in the Edit Value
Input Box. When you are satisfied with the new data, press ENTER.
This will place the value in the highlighted table entry and move the
cursor to the next available table entry.
Node Selection
Crosshairs
Node Selection
Crosshairs
Node to be
Selected

OPTIONS
You may also select the nodes graphically. Click on the XYZ push
button in the Nodal Values input display. This will display a 2D or 3D
view of the model in the Work Window Pane depending upon the
geometry of your model.
For 2D you may enter the coordinates for the node of interest to you or
you may move the cursor to a desired node in the geometry and click
on the left mouse button. When you click near or on a node in the
geometry, PostCAST will display green Node Selection Crosshairs to
help you isolate the node and will display the nodes coordinates in the
appropriate input line. This is illustrated in the figure shown here. If
you press and hold the left mouse button in the Work Window pane,
you can drag the crosshairs to another position in the display. When
you release the mouse button the node closest to the cursor will be
selected.
For 3D models, PostCAST displays a small window with three slider

bars. You can move the slider bars to control the position of the
orthogonal cutting planes. Or you may enter the coordinates as
described above.
When you are satisfied with the selected node, click on the APPLY
push button. This will store the nodal value in the Nodal Values input
display.
You may use either or both the Edit Value input line and XYZ
coordinate selection techniques to enter node numbers. When you are
satisfied with all of the nodal values, click on the EXECUTE push button
in the Nodal Values input display. This will result in PostCAST
selecting the appropriate nodal data for plotting and display the plot.
You may close the Nodal Values input display by clicking the CANCEL
push button.
Node selection--allows you to isolate and clearly display the thermal

behavior of a few selected points in the casting. You may enter up to
100 different node numbers in the Nodal Values input display.

OPTIONS
OPTIONS
OPTIONS in this sub-menu provide the capability to customize, to an
extent, the appearance of the resulting plots. It also allows you to

perform Cooling Curve Analyses. When you click on the OPTIONS
push button a sub-menu is displayed. The contents of this sub-menu
will be determined by the button you clicked in the X-Y menu. The
figure shown here illustrates the options which are available when you
select TEMPERATURE. It also illustrates how PostCAST graphically
indicates the context of the options you are specifying. When you
select an initial menu option other than TEMPERATURE, the OPTIONS
sub-menu will contain only the COLOR, AUTOMATIC, and FEATURE
ANGLE choices. Each push button in this sub-menu affects the
appearance of the plots or is used to perform the Cooling Curve
Analysis.
Each of these sub-menu push buttons will be discussed in this section.
COLOR--is a rotary toggle switch which allows you to specify the

respective colors for the background and the plotted results. By
default, the cooling curves are drawn with various colors.
However, you may find it useful to draw these plots in black on
a white background or in white on a black background.
Successive clicks on this toggle switch will cycle through the
alternatives.
The options are: {COLOR | BLACK/WHITE | WHITE/BLACK}.

The default is COLOR.

OPTIONS
AUTOMATIC/MANUAL--is a toggle switch which allows you to specify

the method to be used for
scaling the Y axis in the
plot. By default, the
temperature (or any other
quantity) on the Y axis is
scaled automatically to
the minimum and
maximum values that
were found among the time steps selected for display. When
you click on the AUTOMATIC toggle switch, a Text Input dialog
box is displayed. As shown in this figure, you may input the
minimum and maximum values you want to use for scaling the
Y axis in the resulting plot. Successive clicks on this push
button will toggle between the AUTOMATIC and MANUAL
methods for scaling the Y axis.
FEATURE ANGLE--determines which element edges of a mesh will

appear in the
geometry plot
while
selecting
XYZ
coordinates.
When you click on the FEATURE ANGLE push button, an
angle input dialog box containing a slider bar is displayed. As
shown in this figure, you may select the degree of the feature
angle by moving the slider in the horizontal scroll bar. You may
move the slider by clicking the left mouse button on either of
the directional arrows--moving the slider one degree at a time,
by clicking the left mouse button in the slide track--jumping the
slider a number of degrees at a time, or by clicking on and
dragging the slider--selecting the degree in a continuous
manner proportionate with the extent of the mouse movement.
The edge between two element faces will be drawn if the angle
between the normals of the two faces is greater than or equal to
the feature angle you select. A feature angle of zero will cause
all element edges to be displayed. The angle selected may be
between zero and 180 degrees.
When you are satisfied with the Feature Angle specified, click
on the SAVE push button below the slider bar to save the
selected value and close the display.

OPTIONS
DT vs TIME--is used to plot the differences between two thermal

histories as a function of time. This plot is available only from
the TEMPERATURE X-Y PLOT option. One of the time-
temperature data sets used in this comparison enters via an
EXTERNAL file, as described above. The other data set is
taken from the numerical results for a specified node number.
You may specify the node number using the NODES capability
described above.
To select this plot, click on the DT vs TIME toggle switch in the

menu. When it has been selected, the checkbox will be
highlighted in burgundy. Successive clicks on this menu item
will toggle DT vs TIME between on and off.
To view the plot, select DT vs TIME, click on the NODES push

button and then select the EXECUTE function a after nodal
value has been assigned.
DT vs TIME and DT vs TEMP are mutually exclusive. If you

select DT vs TIME, DT vs TEMP will be deselected and vice
versa.
DT vs TEMP--is used to plot the differences between two thermal

histories as a function of temperature. This plot is available
only from the TEMPERATURE X-Y PLOT option. This
capability works like the DT vs TIME option, except the
resulting plot will be as a function of temperature. You may
specify the node number using the NODES capability described
above.
To select this plot, click on the DT vs TEMP toggle switch in the

menu. When it has been selected, the checkbox will be
highlighted in burgundy. Successive clicks on this menu item
will toggle DT vs TEMP between on and off.
To view the plot, select DT vs TEMP, click on the NODES push

button and then select the EXECUTE function after a nodal
value has been assigned.

OPTIONS
1st DERIVATIVE--is a toggle switch used to indicate that you want the
first derivative curve drawn when the cooling curve is plotted.
When selected, the checkbox will be highlighted in burgundy.
Successive clicks on this menu item will toggle 1st
DERIVATIVE between on and off. This plot is available only
from the TEMPERATURE X-Y PLOT option.
To view the plot, click on the NODES push button and then
select the EXECUTE function after a nodal value has been
assigned or an external file has been specified. You will be
asked to choose both the start and the end of solidification.
You may do so by using the left mouse button to drag the
cursor to the appropriate locations on the first derivative curve.
You will also be asked to enter the specific heat of the metal.
You may enter an average constant value of the specific heat
(in c.g.s. units).
Generally, the onset of solidification is the temperature

corresponding to maximum in the second derivative curve.
The temperature value corresponding to the minimum in the
first derivative curve (beyond the temperature corresponding to
maximum in first derivative curve) is the point where
solidification ends. This is explained, in more detail, in the
Remarks Section below under Cooling Curve Analysis.
2nd DERIVATIVE--is a toggle switch used to indicate that you want the
second derivative curve drawn when the cooling curve is
plotted. When selected, the checkbox will be highlighted in
burgundy. Successive clicks on this menu item will toggle 2nd
DERIVATIVE between on and off. This plot is available only
from the TEMPERATURE X-Y PLOT option.
select the EXECUTE function after nodal values have been
assigned or external files have been specified.
GRID--is a toggle switch used to indicate whether or not you want to

have a grid displayed when the curves are plotted. When
selected, the checkbox will be highlighted in burgundy.
Successive clicks on this menu item will toggle GRID between
on and off. This function is discussed in further detail in the
Remarks Section below under Cooling Curve Analysis.
select the EXECUTE function after nodal values have been
assigned.

OPTIONS
SMOOTH--provides the capability to smooth an array of points which

are read from an external file. Typically the raw time-
temperature data read by a thermocouple contains a lot of
noise.. The resulting cooling curve needs to be smoothened.
This push button executes a routine to smooth an array of
points that are in order of increasing abscissas. This plot is
available only from the TEMPERATURE X-Y PLOT option
You activate the SMOOTH

capability by clicking the
SMOOTH push button. This
will display an Edit Value
input box. As shown in this
figure, this box allows you to
specify the amount of smoothing desired.
The amount of smoothing to be performed is specified as the

number of points over which the data needs to be smoothed.
Zero gives no smoothing. Any value larger than about half of
the total number of data points will make the output featureless.
Typically, a reasonable value will be between 5 and thirty. To
enter a value, place the cursor in the Input Line, type a integer
value, and click on the APPLY push button.
This function is discussed in further detail in the Remarks

Section below under Cooling Curve Analysis.
Remarks The discussion of syntax and options for Interval, Nodes, and Options
above may be applied to the X-Y PLOT of Temperature, Fraction Solid,
Pressure, and Velocity. External, DTA, first and second derivatives and
smoothing only apply to temperature.
Cooling Curve Analysis--input is the raw time-temperature data as

typically read by a thermocouple placed at a certain location of
a casting. It is read into PostCAST from an external file.
Alternatively, cooling curve analysis can also be done on
simulated nodal temperature data. Usually, one thermocouple
trace is processed at a time. PostCASTs routine for smoothing
cooling curve data, which typically contains a lot of noise, uses
a Fast Fourier Transform to low pass filter the data. Based
upon your input to specify the number of points over which the
smoothing is to be done, a natural cubic spline algorithm is
used to interpolate a curve through these smoothened data
points. The first and second derivative of temperature are also
displayed.
The temperature value corresponding to the maximum in the

OPTIONS
second derivative curve is called TEN. The time value

corresponding to TEN is the start of the solidification. The
temperature value corresponding to the maximum in the first
derivative curve is called MXRRES. The temperature value
corresponding to the minimum in the first derivative curve
beyond the time value corresponding to MXRRES, is called
TES. The time value corresponding to TES gives the time for
end of solidification.
After you have selected the 1st DERIVATIVE and/or 2nd

DERIVATIVE options, the plots have been drawn, and you
have chosen both the start and the end of solidification on the
first derivative curve, a cubic spline curve will be plotted
between those two points, which is basically the derivative of
the zero curve. Also, you will be asked to enter the specific
heat of the metal. You may enter an average, constant value
of the specific heat. The area under the first derivative curve
and the derivative of the zero curve between times
corresponding to TEN and TES gives the latent heat of
transformation, which is calculated by numerical integration.
The latent heat value is then printed on the screen in cgs units,
i.e., cal/gm.
The cooling curve analysis technique can be easily used for the
determination of fraction of solid. By calculating the cumulative
area between the first derivative curve and the derivative of the
zero curve between TEN and TES as a fraction of the total area
between these curves, the values of the total fraction of solid
evolved as a function of time are obtained. When this curve is
differentiated with respect to time, two distinct mechanisms are
noticed. The time rate of the evolution of the fraction of solid
has two parts: one is for the initial nucleation and the other is
for bulk solidification. Usually the rate of change of fraction of
solid curve can be assumed to be a linear function in time. The
coefficients of this curve can easily be determined.
By taking a series of cooling curves at different locations in a

casting and processing each one of them, one can evaluate the
derivative of a fraction of solid curve as a function of time for
each curve. Then considering the effect of the cooling rate, a
general time derivative of fraction of solid curve can be
constructed as a function of time and cooling rate.
In general, this cooling curve analysis technique can be used as

a process control tool. It can be used to determine the
occurrence of various phases during solidification and solid
state transformation of almost all alloys. It can also be used
effectively for control of inoculation in gray iron. The effect of

OPTIONS
inoculation on the formation of austenite can be easily

determined using this technique because the amount of
austenite formed can be determined. Also, carbon equivalent
information can be predicted.
This technique can be used to obtain the latent heat of

solidification of an unknown material, which is a good technique
for characterization of new materials. Also, by using this
technique, one can determine the liquidus and solid
temperatures precisely. In addition, any precipitation of phases
during the cooling process can be easily determined.
The mathematical description of this process can be found in

Appendix C, Mathematical Formulations.
Related Topics TABLE MAINTENANCE, Mathematical Formulations

OPTIONS
OPTIONS
GEOMETRY
Description GEOMETRY is a push button in the OPTIONS menu. It creates an

ASCII file containing the nodal coordinates and element connectivities
as they are extracted from the prefixg.unf file.
Method GEOMETRY is activated by clicking on it. This builds the ASCII file.
This file can be written in either the PATRAN neutral file or the IDEAS
universal file format, depending upon the format selected from the
FORMAT function in the Main Function Banner of PostCAST.
PostCAST displays an information window to indicate that the file has

been built successfully. The figure shown here illustrates this type of
information window. Notice that the name of the file built is displayed
in this information window.
Remarks This geometry file represents the final configuration of the model as it
goes into ProCAST. Accordingly, it will contain any new nodes which
have been generated and any renumbering of elements and nodes that
may have occurred in PreCAST or DataCAST.
Related Topics

OPTIONS
OPTIONS
RADIATION FACE
Description RADIATION FACE is a push button in the OPTIONS menu. It creates

an ASCII file containing the nodal coordinates and element
connectivities of only the faces that are participating in a view factor
radiation model.
Method RADIATION FACE is activated by clicking on it. This results in the

immediate action to build the ASCII file. This file can be written in
either the PATRAN neutral file or the IDEAS universal file format,
depending upon the format selected from the FORMAT function in the
Main Function Banner of PostCAST.

Remarks This file is useful for identifying any gaps in the casting or enclosure
which would cause large row sum errors in the view factor matrix.
Related Topics

OPTIONS
OPTIONS
TEMPERATURE
Description TEMPERATURE is a push button in the OPTIONS menu. It provides

the capability to extract temperature results from the prefixt.unf file,
which is a binary file, and write them to an ASCII file. This file can be
written in either the PATRAN neutral file or the IDEAS universal file
format, depending upon the format selected from the FORMAT function
in the Main Function Banner of PostCAST.
Method TEMPERATURE is activated by clicking on it. This results in the

immediate action to display a sub-menu of push buttons which are the
methods you may use to designate the time step levels to be included
in the output file. The figure shown
here illustrates this sub-menu.
When you select an entry from this

table by clicking the desired option,
the background of that push button is
highlighted in red.
When you select the SPECIFY STEPS or SELECT STEPS options

from this menu, additional input dialog tables will be opened. These
tables provide the capability to specify time step levels to be included in
the output file.
Each of the time step selection push button options, Interval, Specify
Steps, and Select Steps, will be discussed in this section. For
convenience they will be presented in alphabetical order.

OPTIONS
INTERVAL
If you choose INTERVAL, the time step levels will be determined based
upon the values entered in the STEPS function of the Main Function
Banner. The interval chosen must be a multiple of TFREQ, which
controls the frequency of output to the temperature results file.

SPECIFY STEPS
SPECIFY STEPS provides the
capability to directly input the
desired time step numbers.
When you click on the SPECIFY
STEPS push button in the sub-
menu, PostCAST displays the
input display as shown by the
figure here.
Entering data in the table is done

by first selecting the desired table
entry. You select a table entry by
clicking the desired entry. If the
table is empty, select the area in
the first row. This is illustrated in
If the table contains Step Value

information and you want to add
another value, use the scroll bar,
if necessary, to move to the end
of the table and select the first
empty area.

OPTIONS
Once a table entry is selected, the background of that entry will change
Box. You may then enter or change the step value in the Edit Value
Input Box.
You may enter up to 100 different step values. When you are satisfied
with the new data, press ENTER. This will place the value in the
highlighted table entry and move the cursor to the next available table
entry.
If TFREQ has a value greater than one, the step numbers given must
be a multiple of TFREQ. Otherwise, they are ignored.
When all the desired time steps have been entered, click on EXECUTE.
This will save your selections and create the file. You will see the same
message window that appeared for the INTERVAL option.
You may close this display without specifying or changing any time step
values by clicking the CANCEL push button.
SELECT STEPS
SELECT STEPS provides
the capability to select time
levels from the results file.
When you click on the
SELECT STEPS push
button in the sub-menu,
PostCAST displays the input
display as shown the figure
here. It will contain a list of
the time levels in the results
file.
You select the steps to be

output to the ASCII file by
clicking on the desired table
entries. As you select
entries in this list, they will
be highlighted with a red
background. You may
deselect an entry by clicking
on it again with the left
mouse button. Use the
scroll bar, if necessary, to
move to the desired table
entry.

OPTIONS
You may deselect every entry in the list by clicking the CLEAR push
button.
When all the desired time steps have been selected, click on
EXECUTE. This will save your selections and create the file. You will
see the same message window that appeared for the INTERVAL option.
You may close this display without specifying or changing any time step
values by clicking the CANCEL push button.
Remarks The ASCII file created by this function may be used as input for other
analyses or reporting purposes outside of ProCAST.
Related Topics

OPTIONS
OPTIONS
PRESSURE
Description PRESSURE is a push button in the OPTIONS menu. It provides the

capability to extract pressure results from the prefixp.unf file, which is a
binary file, and write them to an ASCII file. This file can be written in
Method PRESSURE is activated by clicking on it. This results in the immediate

action to display a sub-menu of push buttons which are the methods
you may use to designate the time step levels to be included in the
output file. The figure shown here
illustrates this sub-menu.
The options available in this sub-

menu work in the same way as the
OPTIONS--TEMPERATURE menu
item.
Please see the OPTIONS--TEMPERATURE section of this manual for

a description of these menu options, their syntax, and usage.
Related Topics OPTIONS--TEMPERATURE

OPTIONS
OPTIONS
VELOCITY
Description VELOCITY is a push button in the OPTIONS menu. It provides the

capability to extract velocity results from the prefix(u, v, and w).unf
files, which are binary files, and write them to an ASCII file. The three
components of the velocity vector at each node are output for the
selected time levels. This file can be written in either the PATRAN
neutral file or the IDEAS universal file format, depending upon the
format selected from the FORMAT function in the Main Function
Banner of PostCAST.
Method VELOCITY is activated by clicking on it. This results in the immediate


item.


OPTIONS
OPTIONS
HEAT FLUX
Description HEAT FLUX is a push button in the OPTIONS menu. It provides the
capability to extract heat flux results from the prefixq.unf file, which is a
binary file, and write them to an ASCII file. This file can be written in
Method HEAT FLUX is activated by clicking on it. This results in the immediate

item.


OPTIONS
OPTIONS
R, G, L
Description R, G, L is a push button in the OPTIONS menu. It provides the

capability to specify the method for calculating the solidification rate
(R), the method for calculating the temperature gradient (G), the upper
and lower temperature levels to be used in calculating the cooling rate
(L), and the constants to be used in calculating the mapping factor.
Method R, G, L is activated by clicking on it. This results in the immediate

action to display an input dialog box. The figure shown here illustrates
this input dialog box.
Each of the parameters and options in this dialog box will be discussed
in this section.
You may close this display by clicking the CANCEL push button.
R METHOD
This push button is a toggle switch. Successive clicks on this push
button will toggle between method 1 and 2.
In Method 1, when each node reaches the specified temperature, a

point is located along the temperature gradient some distance away and
the time that it takes for the isotherm to reach that point is determined.
R is then calculated as that distance divided by the difference in time.
In Method 2, R is calculated as the cooling rate divided by the

temperature gradient. Method 1 takes longer to compute, but it does
not depend on the cooling rate. The results obtained by Method 2 are
affected by the temperature levels used to calculate L.

OPTIONS
R METHOD options are: {1 | 2}. The default is 1.
G METHOD
This push button is a rotary toggle switch. Successive clicks on this
push button will cycle through the available options. G METHOD
determines if the total magnitude of the temperature gradient or one
component used in the calculation of the mapping factor.
G METHOD options are: {TOTAL | dT/dx | dT/dy | dT/dz}. The default

is TOTAL.
Normally, one would choose TOTAL, in which case, the following

equation describes the magnitude of the temperature gradient.
1
0T 2
0T
2
0T
2
2
0x 0y 0z
L UPPER TEMP and L LOWER TEMP

These input lines specify the temperature levels to be used in the
calculation of the cooling rate, L. The following equation describes the
calculation of the cooling rate; where, T is temperature and t is time to
reach that temperature.
Tupper Tlower
L
tupper tlower

For example, Tupper could be the liquidus and Tlower the solidus.
To enter these temperatures, place the cursor in the appropriate input

line and type the desired value. You may move to the next input field
by moving the cursor or by pressing ENTER.
R, G TEMP
This input line specifies the temperature to be used for the calculation
of the isotherm velocity and the temperature gradient. If R, G TEMP is
set to the solidus, then R will be the solidification rate. However, R can
be calculated as an isotherm velocity for any temperature.
The gradient, G, is computed at a given node when it reaches the R, G

TEMP level. Therefore, G is calculated at a different time for each
node.
To enter this temperature, place the cursor in the R, G TEMP input line
and type the desired value. You may move to the next input field by
moving the cursor or by pressing ENTER.

OPTIONS
MAPPING CONSTANTS
These input lines specify the constants to be used in calculating the
mapping factor. The mapping factor is calculated from the formula
shown here.
M
aRbG cLd
The a, b, c, and d are the user specified constants and correspond to

the MAPPING CONSTANTS input lines. The default values for these
constants yield the Niyama criterion,
G
M
In the literature, L is often expressed as T . If the constant is a given

the value of zero, the mapping factor will not be computed.
You may click on the HELP push button to obtain more information
about various combinations of the constants which produce different
mapping factors.
When all the desired values have been entered, click on APPLY. This
will save your selections and create the mapping factors and mapping
factors log files. A message window will be displayed indicating when
the files have been successfully completed.
You may close this display without specifying or changing any values
by clicking the CANCEL push button.
Remarks R, G, L stands for solidification rate (R), temperature gradient (G), and
cooling rate (L). R is the velocity of a particular isotherm. G is the
gradient calculated at each node when that node reaches a given
temperature. L is the time derivative of temperature, calculated as the
difference of two temperature levels divided by the difference in time at
which those temperatures are reached.
Choosing the R, G, L option will produce all of these results. In

addition, they can be combined into a single product, called a mapping
factor, which can be a useful indicator of many metallurgical features.
The Niyama criteria for porosity is an example.
The mapping factor log contains the temperature levels and the
constant values that were used in calculating R, G, L, and M.
By default, only a binary output file is produced for ViewCAST. If you

select PATRAN or IDEAS under the FORMAT menu, an ASCII file with
the extension "ntl" will also be created. This neutral file contains ten

OPTIONS
columns or sets of data as detailed below:
Column/Set Quantity
1 M
2 L
3 G
4 dT/dx
5 dT/dy
6 dT/dz
7 R
8 Rx
9 Ry
10 Rz
Related Topics

OPTIONS
OPTIONS
FEEDING LENGTH
Description FEEDING LENGTH is a push button in the OPTIONS menu. It

provides the capability to calculate the distance between the solidus
and some user defined critical temperature which represents some
fraction solid beyond which feeding is impaired. This distance is then
compared with a critical feeding length, which is a simple linear
function of the hydrostatic pressure. If the feeding distance exceeds
the critical length, then porosity would be likely.
Method FEEDING LENGTH is activated by clicking on it. This results in the

immediate action to display an input dialog box. The figure shown here
illustrates this input dialog box.
Each of the parameters and options in this dialog box will be discussed
in this section.
You may close this display by clicking the CANCEL push button.
A and B
These input lines allow the user to enter the constants for the critical
feeding length equation. These critical temperatures represent some
fraction solid beyond which feeding is impaired.
To enter these temperatures, place the cursor in the appropriate input

line and type the desired value. You may move to the next input field
by moving the cursor or by pressing ENTER.

OPTIONS
SOLIDUS
This input line is for the solidus temperature of the metal.
To enter this temperature, place the cursor in the appropriate input line
and type the desired value. You may move to the next input field by
CRITICAL
This input line is for a temperature value which corresponds to a
fraction solid greater than zero and less than one. The critical fraction
solid at which feeding is impaired depends on the alloy, but is typically
in the range of .6 to .8.
To enter this value, place the cursor in the appropriate input line and
type the desired value. You may move to the next input field by
When all the desired values have been entered, click on APPLY. This
will save your selections and close the display.
Remarks The critical feeding length is calculated from the formula shown here.
F Lcr
A P B
P is the hydrostatic pressure head. P is calculated automatically from

the geometry of the casting and the metal density.
Related Topics

OPTIONS
OPTIONS
ISOCHRONS
Description ISOCHRONS is a push button in the OPTIONS menu. It provides the

capability to produce contours of the time that it takes to reach specified
temperature levels.
Method ISOCHRONS is activated by clicking on it. This results in the

immediate action to display a sub-
menu which contains two optional
methods for specifying the
temperature levels to be used. The
figure shown here illustrates this sub-
menu.
When you select either option, by clicking on the desired push button,
an input dialog box will be displayed. Each option in this sub-menu will
be discussed in this section.
SEMI-AUTO
Provides the capability to
generate the temperature
levels based upon your input
of two parameters. When
you activate the SEMI-
AUTO push button an input
dialog box is displayed. This
is illustrated in the figure
here.
Twenty temperature levels will be generated using the START value

and incremented by the DELTA value.
START--enter the starting temperature level to be used. Place the

cursor in the appropriate input line, type the desired value, and
press ENTER.
DELTA--enter the amount of temperature change you want between the

generated temperature levels. Place the cursor in the
appropriate input line, type the desired value, and press ENTER.

OPTIONS
Click on the APPLY push button when you are satisfied with the START
and DELTA values. You may close this display by clicking the
CANCEL push button.
SPECIFY TEMPS
SPECIFY TEMPS provides the capability to directly input the desired
temperature levels. When you
click on the SPECIFY TEMPS
push button in the sub-menu,
PostCAST displays the input
display as shown the figure
here.
Entering data in the table is

done by first selecting the
desired table entry. You select
a table entry by clicking on the
desired entry. If the table is
empty, select the area in the
first row. This is illustrated in
If the table contains temperature

information and you want to add
another value, use the scroll
bar, if necessary, to move to the
end of the table and select the
first empty area.
Once a table entry is selected

the background of that entry will change to red and the cursor will be
placed in the Edit Value Input Box. If the entry contains data, the data
will be displayed in the Edit Value Input Box. You may then enter or
change the step value in the Edit Value Input Box.
You may enter up to 50 different temperature levels in this table. When

you are satisfied with the new data, press ENTER. This will place the
value in the highlighted table entry and move the cursor to the next
available table entry.
When you are satisfied with the temperature levels in this table, click on
the EXECUTE push button. This will close this display, calculate the
temperature levels, and build the file.

OPTIONS
With either the SEMI-AUTO or SPECIFY TEMPS method, clicking on

APPLY or EXECUTE will save your input and create the isochrons and
temperature level log files, respectively. A message window will be
displayed indicating when the files have been successfully completed.
Remarks ISOCHRONS are particularly useful for identifying hot spots and
necking.
By default, only a binary output file is produced for ViewCAST. If you

select PATRAN or IDEAS under the FORMAT menu, an ASCII file with
the extension "ntl" will also be created.
Related Topics

OPTIONS
OPTIONS
ALPHA CASE
Description ALPHA CASE is a push button in the OPTIONS menu. It creates an

ASCII file containing information about the thickness of alpha case for
the surface nodes adjacent to the ceramic shell in Titanium alloy
investment castings.
Method ALPHA CASE is activated by clicking on it. This results in the

immediate action to build the output file. This file can also be written in

Remarks The ALPHA CASE option is only used in Titanium castings. In Titanium
castings there is a very brittle alpha ( ) layer that forms on the
casting. The ALPHA CASE is used to predict the thickness of this
layer.
Surface regions of Ti alloy investment castings are usually

contaminated with oxygen due to reactivity of the metal with the
ceramic shell mold during solidification and subsequent cooling from
elevated temperatures. The local increase of O2 content at the surface
promotes the formation of oxygen-rich Ti hexagonal solid solution ( -
phase) at temperatures when bulk alloy is single phase beta ( ). This
also alters the alpha/beta structure near the surface during cooling to
room temperature.

OPTIONS
Usually the thickness of this brittle layer ranges from 50 to 2000

microns. This leads to deterioration of surface mechanical properties
and it must be removed by chemical milling before use.
The thickness of the layer needs to be predicted to determine milling

time and to determine excess thickness to be factored into the design of
as-cast dimensions. The model assumes a few typical numbers for O2
concentration at the surface, bulk region, and at the edge of the alpha
case region. Also, standard values are obtained for the diffusion
coefficient and activation energy from the literature.
The ALPHA CASE option is only used in Titanium castings. In Titanium

castings there is a very brittle oxide layer that forms on the casting.
The ALPHA CASE is used to predict the thickness of the oxide layer.
Related Topics

OPTIONS
OPTIONS
SDAS
Description SDAS is a push button in the OPTIONS menu. It provides the

capability of calculating the Secondary Dendrite Arm Spacing (SDAS)
based upon the thermal history.
Method SDAS is activated by clicking on it. This results in the immediate action
to display an input dialog box. The
figure shown here illustrates this
dialog box.
Each parameter in this dialog box will

be discussed in this section.
You may close this display and move

to another function of PostCAST or
to another function of OPTIONS by
clicking the appropriate Main Function Banner or Menu push button
respectively.
SDAS is calculated according to the following:
SDAS = ( M * (tend - tstart))exp

Where:
tend = time to reach Tend
tstart = time to reach Tstart
TSTART
Normally taken as the liquidus. Enter the temperature value to be used
by placing the cursor in the appropriate input line, typing the desired
value, and pressing ENTER.
TEND
Normally the eutectic temperature. Enter the temperature value to be
used by placing the cursor in the appropriate input line, typing the
desired value, and pressing ENTER.

OPTIONS
EXPONENT
Provides the capability to enter the exponent to be used in the formula
shown above.
Enter the exponent by placing the cursor in the appropriate input line,
typing the desired value, and pressing ENTER.
M
Provides the capability to specify the coarsening constant and is alloy
dependent.
Enter the coarsening constant to be used by placing the cursor in the

appropriate input line, typing the desired value, and pressing ENTER.
When you are satisfied with the values you have entered, click on the
APPLY push button. This will close this display, extract the appropriate
data, and build the ASCII file. A message window will be displayed
indicating when the files have been successfully built.
Remarks In practice there is a

correlation between
the SDAS and
mechanical
properties. The
finer the spacing of
the SDAS, the
greater the strength.
The figure here,
illustrates what SDAS is.
Related Topics

OPTIONS
OPTIONS
ROW SUM ERROR
Description ROW SUM ERROR is a push button in the OPTIONS menu. It creates
an ASCII file containing the nodal values of row sum errors, if a
simulation used the view factor radiation capabilities. These are
averaged from the row sum errors on the faces surrounding each node.
Only the nodes on the radiating surfaces will have non-zero values.
Method ROW SUM ERROR is activated by clicking on it. This results in the

Remarks PostCAST looks for a file produced by ProCAST with the name
prefix.serr. This file is output from ProCAST if the value of one has
been added to RDEBUG in the prefixp.dat file.
Related Topics

OPTIONS
OPTIONS
FACE TO GROUP
Description FACE TO GROUP is a push button in the OPTIONS menu. It creates

an ASCII file containing the nodal values of aggregate view factors.
This option is only available if a simulation used the view factor
radiation capabilities. It is not necessary to create this ASCII file if you
are using ViewCAST for graphical postprocessing.
Method FACE TO GROUP is activated by clicking on it. This results in the


Remarks A face to group view factor is the fraction of the view space from a
face that is occupied by one group. A group is an assembly of
enclosure or solid faces that have the same boundary condition. The
nodal values are averaged from the surrounding face values. Only the
nodes on the radiating surfaces will have non-zero values.
PostCAST will look for a file produced by ProCAST with the name
prefix.view. This file is output from ProCAST if the value of two has
been added to RDEBUG in the prefixp.dat file.
Related Topics

FORMAT
FORMAT
Description FORMAT is a push button in the Main Function Banner. This function
of PostCAST enables you to specify the type of ASCII results files to be
produced. When you activate the FORMAT push button, a menu is
opened which will allow you to choose the specific output file format to
be used.
Method FORMAT is activated by clicking on it. The resulting menu is shown

here.
You select either the PATRAN neutral file

format or the IDEAS universal file format
by clicking on the check box to the left of
either label in the menu. When you
select a format, the background of the respective check box will be
highlighted in red.
These check boxes may be toggled between on and off by successively

clicking the check box. Additionally, these check boxes are mutually
exclusive.
You may leave the FORMAT function by clicking another push button in
the Main Function Banner.
Remarks If you are using ViewCAST for graphical postprocessing, it is not

necessary to choose either PATRAN or IDEAS to see the results.
You do need to pick one or the other for the GEOMETRY and
RADIATION FACE options.
Related Topics OPTIONS--RADIATION FACE, OPTIONS--GEOMETRY

STEPS
STEPS
Description STEPS is a push button in the Main Function Banner. This function
enables you to control the time steps used in various operations of
PostCAST. When you activate the STEPS push button, a menu is
opened which will allow you to enter time step parameters. Each of
these parameters available from this menu will be discussed in this
section.
Method STEPS is activated by clicking on it. The resulting menu input dialog
box is shown here.
You select the parameter by

clicking the desired
parameter. When a
parameter is selected, its
background will be
highlighted in red.
You may leave the STEPS

function by clicking another
push button in the Main
Function Banner.
START
Specifies the beginning time step. Enter the beginning time step by
selecting START, placing the cursor in the Edit Value input line, typing
the desired value, and pressing ENTER.
END
Specifies the ending time step. Enter the ending time step by selecting
END, placing the cursor in the Edit Value input line, typing the desired
value, and pressing ENTER.
FREQUENCY
Specifies the frequency of the time steps to be used between the
START and END values. Enter the frequency by selecting
FREQUENCY, placing the cursor in the Edit Value input line, typing the
desired value, and pressing ENTER.
Remarks The parameters given under STEPS determine which time levels are
used when plotting the temperature-time curves. They control the time
levels for which results are output in the ASCII files for temperature,
pressure, velocity, and heat flux. The calculations performed for R, G,
L, FEEDING LENGTH, and ISOCHRONS are all based upon the
temperature results available at the time levels chosen under STEPS.

STEPS
You can speed up these computations by using a FREQUENCY greater

than one because not as many data points have to be examined.
However, the accuracy of the results may be diminished by using too
large a value for FREQUENCY.
The values for START, END, and FREQUENCY should be multiples of

VFREQ for pressure and velocity, and multiples of QFREQ fro heat
flux. For all other cases, they should be multiples of TFREQ.
The beginning and ending time steps, and the frequency that are
specified here are used in the following functions:
1. X---Y PLOT, TEMPERATURE, INTERVAL option
2. X---Y PLOT, FRACTION SOLID, INTERVAL option
3. X---Y PLOT, PRESSURE, INTERVAL option
4. X---Y PLOT, VELOCITY, INTERVAL option
5. TEMPERATURE, INTERVAL option
6. PRESSURE, INTERVAL option
7. VELOCITY, INTERVAL option
8. HEAT FLUX, INTERVAL option
9. R, G, L
10. FEEDING LENGTH
11. ISOCHRONS
Related Topics

UNITS
UNITS
Description UNITS is a push button in the Main Function Banner. This function of
PostCAST enables you to specify the units of measure to be used in the
ASCII output files.
Method UNITS is activated by clicking on it. This results in the immediate

action to display a dialog box containing a list of the unit of measure
types. Next to each category of units is a rotary toggle switch which will
display the available
options for each of
the categories.
these toggle switches
will cycle through the
available options.
The figure shown

here illustrates the
UNITS dialog box.
The UNITS
parameters and the
available options for
each parameter will
be presented here. For convenience in presentation, they will be
HEAT FLUX--specifies the heat flux units to be used in the outputs.

The default is specified in QUNITS in the prefixp.dat file.
LENGTH--specifies the length units to be used in the outputs.

Choose from: {m | cm | mm | ft | in}
The default is centimeters.
PRESSURE--specifies the pressure units to be used in the outputs.

The default is specified in PUNITS in the prefixp.dat file.

UNITS
TEMPERATURE--specifies the temperature units to be used in the

outputs.
The default is specified in TUNITS in the prefixp.dat file.
VELOCITY--specifies the velocity units to be used in the outputs.

The default is specified in VUNITS in the prefixp.dat file.
by clicking the appropriate Main Function Banner.
Remarks The length units are used in the temperature gradient and feeding
length calculations.
The temperature units are used in the TEMP-TIME PLOTS,

TEMPERATURE, R, G, L, FEEDING LENGTH, and ISOCHRON
functions.
Heat Flux, Pressure, and Velocity units affect their respective output in
the ASCII results files.
Related Topics RUN PARAMETERS--UNITS

MATERIALS
MATERIALS
function of PostCAST enables you to specify the material regions of the
model that are to be active in the calculations of the [R, G, L],
FEEDING LENGTH,SDAS, X-Y PLOTS, GEOMETRY,
TEMPERATURE, and ISOCHRONS functions.
Method MATERIALS is activated by clicking on it. This results in the immediate

action to display a list of all the materials in the model.
The figure shown here illustrates the MATERIALS list.
All materials that are highlighted

in red will be active in the
calculations.
Materials may be excluded from

these calculations by clicking the
left mouse button on the row
associated with the material to
be deactivated.
You may deactivate all materials

by clicking the ALL push button
in the Materials List display.
You may reactivate a material
by clicking on the materials entry in the list.
You may close this display without saving any settings you may have
made by clicking the CANCEL push button.
Remarks You can speed up the calculation process for your model by
deactivating the materials for which the [R, G, L], FEEDING
LENGTH,SDAS, X-Y PLOTS, GEOMETRY, TEMPERATURE, and
ISOCHRONS results are not of interest. Usually, you can turn off
everything but the casting material.
Related Topics

MATERIALS

USING VIEW CAST
CHAPTER 7
USING ViewCAST
Description ViewCAST provides the capability to visualize the results of the
simulation. ViewCAST performs rapid contour plots of all results based
upon time step intervals which you may specify. For example,
temperature contours can be plotted at every time step automatically,
giving an animated effect. Also a cutting plane option allows you to see
inside the casting. You may choose from extensive menus of contours
and vectors for viewing.
Method ViewCAST runs in a either a Unix or a Microsoft Windows NT session

window.
ViewCAST can be started using the following command line instruction

viewcast {prefix} [ -m, -G ] ENTER
ViewCAST may also be started from the EXECUTE menu in the PCS
screen.
The -m optional parameter is a switch for memory usage.

The -G optional parameter is a switch for graphics statistics.
Remarks If you start a ViewCAST session without the prefix parameter shown
above, you will be given an error message in the session window and
prompted to enter a prefix.
Operational procedures and standards at your installation may specify

additional start-up requirements such as passwords, working directory
specifications, and project or file naming conventions. Consult your
installation or network manager for these guidelines.
The general procedure for viewing a contour or a vector is as follows:

1. Run PostCAST to extract/calculate the desired data. For some
contours, you must use PostCAST to process the simulation
results in order to extract the data of interest to you. For
example, in ViewCAST you can display an ISOCHRON contour
which shows the time required to reach a given temperature.
Running PostCAST is only necessary for a subset of all

variables. These are: Isochrons, Mapping Factors, Cooling
Rates, Isotherm Velocity, Temperature Gradients, Alpha Case,
SDAS, and Feeding Length.
2. Set the desired Steps, Parameters, and Materials for viewing.
ViewCAST enables you to tailor the visualization of results to
USING VIEW CAST, PAGE 7 - 1

USING VIEW CAST
best suite your analysis requirements. You can use the Steps
function to display a specific time step or a selected range of
time steps. The Materials function allows you to choose, based
upon material region, the results to be displayed. The
Parameters function allows you to refine the presentation of the
data during viewing. For example, you may adjust the units of
measure, color legend, background color, and whether the
visualization will be presented in a continuous or single step
mode.
3. Activate the view. This function of ViewCAST displays the results.
The graphic display window will be redrawn to show the
material regions corresponding to your selection. Additionally,
during Single Step, a set of up to four push buttons will be
displayed in the lower right corner of the graphics display.
These push buttons allow you to; STore a copy of the image in
a file or Print a copy of the image. While the right arrow and
left arrow allow you to step forward and backward, respectively
through the results. These buttons are shown here along with
the dialog box which is displayed when you select the STore
option. This dialog box allows you to name the file to be
created when storing the image.
The number of buttons shown is determined by ViewCAST
based upon the context and the specific results in which you
are working. For example, if you are displaying Isochrons,

ViewCAST will display the first plot corresponding to the first
temperature you specified. It will also display all four push
buttons. This will allow you to step through all of the Isochrons
generated in PostCAST. If you are viewing the results in the
Continuous Mode and click on PAUSE, The STore and Print
buttons will be displayed.
When ViewCAST is activated, it will display a work space, the UES logo
in the lower right-hand corner, and a Main Function Banner across the
top of the work space. You may use the push buttons in this banner to
navigate through the function menus of ViewCAST.

USING VIEW CAST
These Function Banner buttons are:

CONTOUR,
VECTOR,
STEPS,
PARAMETERS,
MATERIALS,
VIEW,
PAUSE, and
EXIT
right placement in the Function Banner. This also approximates the
order in which you would ordinarily use the functions of ViewCAST.
Related Topics CONTOUR, VECTOR, STEPS, PARAMETERS, MATERIALS, VIEW,

PAUSE, EXIT

CONTOUR
CONTOUR
Description CONTOUR is a push button in the Main Function Banner. This function
of ViewCAST enables you to select the category of analysis results to
be viewed. The CONTOUR push button displays a menu. The options
in this menu represent categories of simulation results. The functions
available from this menu will be discussed in this section.
Method CONTOUR is activated by clicking on it. The initial menu is shown

this menu, ViewCAST displays sub-
menus which itemize the optional classes
of contours which are available.
This menu and the subsequently

displayed sub-menus are lists of mutually
exclusive contour options. Only one
contour option can be active at a time.
After the first selection has been made,
subsequent selections will cancel the
previously chosen contour option. When you select a contour from a
menu, it will be highlighted with a blue background and the menu and
sub-menu will be closed.
To display the contour, click on the VIEW push button in the main
function banner and then click on PICTURE.
You may deactivate all contours by clicking the NONE menu option.
You may leave the CONTOUR function by clicking another push button
in the Main Function Banner. Each Contour Group will be discussed in
the Remarks Section immediately below.
Remarks The CONTOUR function of ViewCAST provides the capability to view

the results of the ProCAST simulation from perspectives which will
support your specific analytical requirements. For convenience, these
views have been grouped as shown in the menu list above. Each of
these groups will be discussed here.

CONTOUR
THERMAL Contours
The figure shown here illustrates the THERMAL sub-menu and displays
the temperature-related views which are
available.
TEMPERATURE, FRACTION SOLID,

HEAT FLUX, and SOLIDIFICATION
TIME contours will be available if a
thermal analysis has been run with
ProCAST.
ISOCHRONS, MAPPING FACTORS,

COOLING RATES, TEMPERATURE
GRADIENTS, ISOTHERM VELOCITY,
FEEDING LENGTH, ALPHA CASE, and
SDAS data is calculated by PostCAST
from temperature results.
Setting the POROS parameter in the Thermal Run Parameters to a

value of 1 will make the MACRO POROSITY data available, and
setting the POROS parameter to a value of 2 will make the GAS
POROSITY and the BUBBLE RADIUS results available.
Temperature--displays the temperatures present, at specific time steps,

in the model. A temperature contour is illustrated below.

CONTOUR
Fraction Solid--displays a representation of the amount of solidification

which has taken place in the model at specific time steps. A
fraction solid contour is illustrated here.
Heat Flux--displays a representation of the rate of heat flow, per unit

area.
Isochrons--display a plot of the time taken to get to a specified
temperature. The Isochrons which are available for viewing
depend upon the selection you make in the
OPTIONSISOCHRONS function of PostCAST. The example
shown here illustrates the elapsed time, in various portions of
the casting, to reach 1070(C.
Mapping Factors--plots the results of the quantity calculated from the

combination of R, G, and L and is generally used as a porosity
indicator.

CONTOUR
Cooling Rates--displays the cooling rates in degrees per unit of time

between the temperatures specified in the R, G, L options of
PostCAST. In this example, the cooling rates were calculated
between the pour temperature of 1385 and 1000(C.
Temperature Gradients--displays the magnitude and direction of the

spatial change of temperature. The gradient is composed of
the x, y, and z components. The example shown here,
illustrates the four views which ViewCAST provides. In practice
these temperature gradients can identify the degree of

temperature variation in the model.

CONTOUR
Isotherm Velocity--plots the results of the solidification rate (R) or

velocity of the isotherm value specified in the R, G, L, Option of
PostCAST.
Feeding Length--displays a plot of the distances between the solidus
and a user defined temperature that represents some fraction
solid beyond which feeding is impaired. This is a porosity
indicator.
Solidification Time--displays a plot of the time from the beginning to the
end of solidification. In the example shown here, the
solidification time is illustrated with a cross section of the
casting.
Macro Porosity--displays the results of the macro porosity calculations.

Gas Porosity--displays the results of the porosity effects associated with
a dissolved gas.
Bubble Radius--displays a plot of the bubble radius as a result of the
gas porosity calculations.
Alpha Case--displays the results of the calculation of Titanium oxide
formation.
Secondary Dendrite Arm Spacing (SDAS)--plots the results of an SDAS
analysis.

CONTOUR
FLUID Contours
The figure shown here illustrates the FLUID sub-menu and displays the
fluid-related views which are available.
The U, V, W are the velocity components
in the X, Y, and Z directions respectively.
PRESSURE and VELOCITY contours will

be available if a fluid flow analysis has
been run with ProCAST.
If the fluids analysis has been run with the

--- turbulence model turned on, the
TURBULENT ENERGY, TURBULENT
DISSIPATION, and TURBULENT VISCOSITY contours will be
available.
If the fluids analysis has been run with the NNEWTON parameter set to
1 or 2, the NON-NEWTONIAN SHEAR RATE and VISCOSITY
contours will be available.
RADIATION Contours
The figure shown here illustrates the RADIATION sub-menu and
displays the radiation-related views which
are available.
Row Sum Errorsdisplays a contour of

the nodal values of the row sum errors. These errors are
caused by gaps in the casting or enclosure.
Face To Group View Factorsdisplays the nodal values of aggregate
view factors. A group is an assembly of enclosure or solid
faces that have the same boundary condition. The nodal
values are averaged from the surrounding face values.
These contours are available if a radiation analysis was run with view
factors specified. The RDEBUG parameter in the prefixp.dat file should
have the values of 1 and 2 added to it in order to cause ProCAST to
produce the files prefix.serr and prefix.view.

CONTOUR
STRESS Contours
The figure shown here illustrates the STRESS sub-menu and displays
the stress-related views which are
available.
The state of stress at a point can be

characterized by three normal
components, )x , )y, )z, and three shear
components, )xy, )yz, )xy. )xy is the shear
stress in the x direction on the y plane
and so on. It is possible to find three
planes going through this same point on
which the shear stress is zero and there is
only a normal stress. These are called
the principal stresses, )1, )2, )3, ranked
in descending order of magnitude. These
are the roots of the following cubic
equation:
3 ( x + y + z ) 2 + ( x y + y z + x z xy2 yz2 xz2 )

( x y z + 2 xy yz xz x yz2 y xz2 z xy2 ) = 0
Effective Stressis an invariant combination of the principal stresses

that gives a single value representation of the state of stress,
rather than a tensor. This value is used for checking the
condition for yielding, i.e., plastic deformation. It is equivalent
to the Von Mises stress, given by the formula:
1 3
m ax =
2
Maximum Shear Stressis also used sometimes as a criteria for
yielding. It is given by the formula:
[ ]
2 1/ 2
= ( 1 2 ) 2 + ( 2 3 ) 2 + ( 3 1 ) 2
2
Average Normal Stressis also known as the hydrostatic or mean

stress. It is given by the formula:
1 + 2 + 3 x + y + z
m = =
3 3
Principal Stress 1--stress resolved to the direction the highest
magnitude of stress.
Principal Stress 2stress resolved to the direction perpendicular to
Stress 1.
Principal Stress 3stress resolved into or out of the plane described by
Stresses 1 and 2.
Sigma X--stress resolved to the x direction.

CONTOUR
Sigma Y--stress resolved to the y direction.

Sigma Zstress resolved to the z direction.
Sigma XY--shear stress in the x-y plane.
Sigma YZ--shear stress in the y-z plane.
Sigma ZX--shear stress in the z-x plane.
Effective Plastic Strain--displays a representation of normalized strain
after it goes plastic. Strain--the change in relative positions of
points in a medium as the result of stress-produced
deformation.
X Displacement--the amount of deformation in the x direction.
Y Displacement--the amount of deformation in the y direction.
Z Displacement--the amount of deformation in the z direction.
MICRO contours
A MICRO sub-menu displays the micro model-related views which are
available. The actual sub-menu which will be displayed will depend
upon the type of analysis that has been performed. The outputs from
all the different micromodels are described in the Appendix.
ELECTROMAGNETICS Contours
The figure shown here illustrates the
ELECTROMAGNETICS sub-menu and
displays the electromagnetic-related
views which are available.
A = magnetic vector potential. This is a
complex number, with real and imaginary
components. This sub-menu allows you
to provide each of the components of A.
They include: Real Ax, Imaginary Ax,
Real Ay, Imaginary Ay, Real Az,
Imaginary Az, and Magnitude A.
Induction Heating--is the heat generated by induced current.
Eddy Current--is the electric current induced by magnetic field.
Real B--magnetic flux density.
Imaginary B--magnetic flux density.
Lorentz Force--plots the force on a fluid due to the presence of an
electric current and magnetic field.
Related Topics Maxwells equations in APPENDIX C

VECTOR
VECTOR
Description VECTOR is a push button in the Main Function Banner. This function
of ViewCAST enables you to select a vector plot of selected analysis
results. The VECTOR push button displays a menu of choices for
producing vector plots. The functions available from this menu will be
Method VECTOR is activated by clicking on it. The resulting menu is shown

here. The options in this menu are
mutually exclusive. Only one vector plot
option can be active at a time. After the
first selection has been made,
subsequent selections will cancel the
previously chosen option. When you
select a vector option from the menu, it
will be highlighted with a blue background
and the menu will be closed.
It is possible to have vector plots superimposed on contour plots. For

example, fluid velocity vectors displayed on top of temperature
contours can provide a great deal of information in viewing filling
transient results. To superimpose a vector plot on a contour plot, select
the desired contour by clicking on it in the CONTOUR menu and then
select the desired vector from the VECTOR menu. The example below
illustrates how the Fluid Velocity Vector plot is superimposed on the
Fluid VelocityMagnitude Contour.
To display the plot, click on the VIEW push button in the main function
banner and then click on PICTURE.
You may deactivate all vectors by clicking the NONE menu option.
You may leave the VECTOR function by clicking another push button in
the Main Function Banner. Each menu option will be discussed in the
Remarks Section immediately below.
Remarks The VECTOR function of ViewCAST provides the capability to view the

VECTOR
magnitude and orientation for selected results from a ProCAST

simulation.
FLUID VELOCITY--Fluid Velocity vectors will be available if a flow

analysis has been run with ProCAST. This plot displays the
magnitude and direction of the fluid flow at specific time steps.
The illustrations shown here demonstrate the capability to zoom
in on portions of the model and examine the plot at different

time steps.
The TEMPERATURE GRADIENTS and ISOTHERM VELOCITY

options require that the R, G, L function be executed using PostCAST
to extract these vector quantities from the thermal results.

VECTOR
TEMPERATURE GRADIENTSdisplays the magnitude and direction of

the temperature change. In the example shown here, the
temperature gradient is plotted based upon the temperature of

1153(C which was specified in the R, G, L Options of
PostCAST.
ISOTHERM VELOCITY---plots the vector results of the solidification

rate (R) or velocity of the isotherm value specified in the R, G,
L, Option of PostCAST. In the example shown here, the
isotherm velocity is plotted based upon the temperature of
1153(C.

VECTOR
HEAT FLUXdisplays the heat transfer into or out of the model. This
vector plot is illustrated here.
REAL B FIELDdisplays the magnetic flux density. Electromagnetic
flux is described by a complex number. This vector plots the

flux associated with the real component of that number.
IMAGINARY B FIELDdisplays the magnetic flux density.
Electromagnetic flux is described by a complex number. This
vector plots the flux associated with the imaginary component
of that number.
Lorentz Forceplots the force on a fluid due to the presence of an
electric current and magnetic field.
Related Topics

STEPS
STEPS
Description STEPS is a push button in the Main Function Banner. This function of
ViewCAST enables you to control which time levels are used in the
sequence of contour plots of temperature, pressure, velocity, and heat
flux. These time steps will also be applied to fluid velocity vector plots.
The STEPS push button displays an input dialog box.
Method STEPS is activated by clicking on it. The list and dialog input box,
shown here, will be displayed.
To enter a value for any of the three

options, select the option by clicking on
the desired entry in the list. The
background of the selected entry will be
highlighted in red. Then insert the cursor
in the text input line, type the desired
value, and press ENTER. The value you
typed will be displayed in the respective entry in the list and the
background of the next entry in the list will be highlighted in red.
You may enter or change any value in the list by repeating the select-
type-ENTER procedure described above. The entries in this list define
the following:
START--specifies the first time step to be displayed for viewing.
END--specifies the last time step to be displayed for viewing.
FREQUENCY--specifies the number of steps between successive
displays.
You may leave the STEPS function by clicking another push button in
the Main Function Banner.
Remarks Depending upon the options you selected in the CONTOUR and
VECTOR menus, the values given for START, END, and FREQUECY
should be multiples of TFREQ, VFREQ, SFREQ, MFREQ, or QFREQ.
Related Topics

MATERIALS
MATERIALS

function of ViewCAST enables you to specify the material regions of the
model which are to be displayed in the graphics area.
Method MATERIALS is activated by clicking on it. This results in the immediate

action to display a list of all the materials in the model.
The figure shown

here illustrates the
MATERIALS list.
Initially, all materials

will be highlighted
with a red
background and will
be displayed.
Materials may be
excluded from these
calculations by
clicking the left
mouse button on the
row associated with
the material to be
deactivated.
You may deactivate all materials by clicking the ALL push button in the
Materials List display.
You may reactivate a material by clicking on the materials entry in the

list.
You may close this display and move to another function of ViewCAST
by clicking the appropriate Main Function Banner or by clicking the
QUIT push button.
Remarks As an example of how you may use this feature, consider removing the
mold elements from the display. This would allow you to view the
casting by itself. Selections in this window do not alter the results or
data files, they merely specify which mesh elements will be displayed in
the graphics viewing area.
Related Topics
PARAMETERS

PARAMETERS
Description PARAMETERS is a push button in the Main Function Banner. This

function of ViewCAST enables you to manage the graphical output
which will be displayed. The options in this menu allow you to control
the color coding used to display contours and vectors, adjust the
intensity and hue of the colors used, label the output displays, and
display complete geometries which were modeled using rotational or
mirror symmetry. The functions available from this menu will be
Method PARAMETERS is activated by clicking on it. The initial menu is shown

this menu, ViewCAST displays additional
Dialog Boxes, Option Lists, Data Input
Windows, or sub-menus. These
graphical interface tools will guide you
through the process of specifying,
the options and their alternative
attributes.
Some of these switches, such as

REVERSE VIDEO, toggle between on
and off. Some other toggle switches,
such as ALL VECTORS, are rotary toggle
switches and cycle through the available
alternatives for display attributes.
You may leave the PARAMETERS

function by clicking another push button
in the Main Function Banner. Each
PARAMETERS menu item will be discussed immediately below.
REVERSE VIDEO
REVERSE VIDEO is a toggle switch which toggles between ON and
OFF. In the ON position, the background color of the contour and
vector plots will be displayed in white. In the OFF position, which is the
default, the background will be displayed in black. This may be useful,
at times, for hard copy output. The toggle button is highlighted in
maroon to indicate the ON position.

PARAMETERS
AUTOMATIC
AUTOMATIC is a toggle switch which toggles between ON and OFF. In
the ON position, which is the default, the color coding for displaying
contours will be determined by dividing the entire range of values of the
variable to be displayed into equal segments. Each of these calculated
segments will be assigned to one of fifteen colors. The toggle button is
highlighted in maroon to indicate the ON position.
AUTOMATIC is toggled to the OFF position when you select and

activate either the SEMI-AUTO or MANUAL options of the
PARAMETERS menu.
SEMI-AUTO
SEMI-AUTO provides the capability for
you to define the color coding to be used
for displaying contours. ViewCAST will
determine the range of values to be
assigned to a color based upon the
values you provide. When you select
SEMI-AUTO, the list and dialog input box,
To enter a value, select the list item by clicking on it. The background
of the selected entry will be highlighted in red. Then insert the cursor in
the text input line, type the desired value, and press ENTER. The value
you typed will be displayed in the respective entry in the list and the
the following:
BASE--specifies the initial value of the attribute to be displayed upon
which all display segments will be based.
DELTA--specifies the size of the range of values to be included in
each of the fifteen color segments. The delta may be either
positive or negative, depending on whether you want the levels
to go up or down from the base value.
Each of these calculated segments will be assigned to one of fifteen

colors. The toggle button is highlighted in maroon to indicate the ON
position. You may turn off the SEMI-AUTO option by activating either
the AUTOMATIC or MANUAL options of the PARAMETERS menu.
You may leave the SEMI-AUTO option by clicking another push button
in the Main Function Banner or by clicking the QUIT push button.

PARAMETERS
MANUAL
MANUAL provides the capability for you
to define the color coding to be used for
displaying contours. When you use this
option, you assign specific values to be
associated with a color segment. When
you select MANUAL, the list and dialog
input box, shown here, will be displayed.
To enter a value, select the list item by

clicking on it. The background of the
selected entry will be highlighted in red.
Then insert the cursor in the text input
line, type the desired value, and press
ENTER. The value you typed will be
displayed in the respective entry in the list
and the background of the next entry in
the list will be highlighted in red.
You may enter or change any value in the

list by repeating the select-type-ENTER
procedure described above.
Each of entered value will be assigned to a color for display purposes.

The toggle button is highlighted in maroon to indicate the ON position.
You may turn off the MANUAL option by activating either the
AUTOMATIC or SEMI-AUTO options of the PARAMETERS menu.
You may save these color assignments by clicking the STORE push
button and entering a file name in the Input Dialog Box which will be
displayed.
You may leave the MANUAL option by clicking another push button in
the Main Function Banner or by clicking the DONE push button.

PARAMETERS
FREE SURFACE
This toggle switch allows you to watch the progression of the free
surface front of the fluid. This option is available only if you run a 3D
solution. The figure shown here illustrates the free surface of a die cast
part.
ENCLOSURE
This toggle switch allows you to visualize the enclosure mesh, if one is
present. This is only used for radiation problems.
UNITS
UNITS is activated by clicking on it. This
results in the immediate action to display
a dialog box containing a list of the unit of
measure types. Next to each category of
units is a rotary toggle switch which will
display the available options for each of
the categories. Successive clicks on
these toggle switches will cycle through the available options. The
UNITS parameters and the available options for each parameter will be
presented here. For convenience in presentation, they will be
HEAT FLUX--specifies the heat flux units to be used in the outputs.

The default is specified in QUNITS in the prefixp.dat file.
PRESSURE--specifies the pressure units to be used in the outputs.

The default is specified in PUNITS in the prefixp.dat file.
STRESS--specifies the stress units to be used in the outputs.

PARAMETERS
Choose from: {N/m**2 | Pa | Kpa | Mpa | bar | dyne | cm**2 |

atm | psia | Ksi | lb/ft**2}
The default is N/m**2 .
TEMPERATURE--specifies the temperature units to be used in the

outputs.
The default is specified in TUNITS in the prefixp.dat file.

VELOCITY--specifies the velocity units to be used in the outputs.
The default is specified in VUNITS in the prefixp.dat file.
You may close this display and move to another function of ViewCAST
CONTINUOUS
CONTINUOUS is a toggle switch which toggles between
CONTINUOUS and SINGLE STEP modes of displaying contours and
vectors. In the CONTINUOUS mode, contour and/or vector plots which
are viewed in a time sequence will be displayed from the starting to the
ending time level without user intervention. This allows you to view the
results as though they were animated.
In the SINGLE STEP mode, you can step forward or backward between
time levels. This is useful if you want to study one image at a time or to
obtain a hard copy of the image. Successive clicks on this menu option
will toggle between CONTINUOUS and SINGLE STEP.

PARAMETERS
ADJUST COLORS
ADJUST COLORS allows you to customize the individual colors in the
spectrum. You can then save your modified spectrum in a named file.
You can create as many different spectra as you like.
When you select ADJUST COLORS, the display illustrated above is

presented. The vertical color bar on the right shows the existing colors
in the spectrum.
To edit a color, click on the desired color entry in the vertical color bar.
The selected color will be highlighted with a white border and that color
will be displayed in the display box. This display box, appearing
horizontally in the window allows you to adjust the red, green, and blue
(RGB) values of the color using the three slider bars. You may move
the sliders by clicking and holding the left mouse button when the
cursor is over the slider knob. While you are depressing the mouse
button, you may drag the knob in either direction. You may also
increment and decrement these values by a value of one by clicking on
the right or left arrows (><). The color square in the horizontal window
changes instantaneously as the RGB values change.
The current RGB value, between 0 and 255, for each color are
displayed above the respective slider bar. When you are satisfied with
the appearance of the color, click on the SAVE push button in the
horizontal window. The modified color will be placed in the vertical
color bar and the next color in the color bar will be loaded for editing.

PARAMETERS
You may also move directly to a particular color by clicking on it.
Once you have finished modifying the colors in the spectrum, you can
save this set by clicking the STORE push button. A Text Input window
will be displayed. In this window, enter a file name and press ENTER.
You type in any name without an extension, the extension color will be
added to the name you give. This file will be located in the ProPATH
directory, which is where all the other ProCAST libraries are kept. The
default color spectrum is kept in a file named view.color.
A previously generated spectrum can be read back in by pressing the

READ button. The same Text Input window will be displayed for you to
enter the filename. Type the desired file name, without extension, and
press ENTER. Once loaded, a previously defined spectrum may be
modified and saved.
You may close the ADJUST COLORS function without saving any
changes by clicking the QUIT push button. You may also select
another ViewCAST function from the Main Function Banner.
FEATURE ANGLE
FEATURE ANGLE allows you to specify which element edges of a
mesh will appear in a plot. Sometimes it is desirable to see the finite
element mesh superimposed
on a plot of the results to aid
in locating various
phenomena. Other times,
the mesh adds visual clutter. The FEATURE ANGLE function lets you
control how much of the mesh you see.
When you select FEATURE ANGLE, the slider bar illustrated here is
displayed. Values available range from 0 to 180 degrees. The edge
between two element faces will be drawn in the plot if the angle
between the normals of the two faces is greater than or equal to the
feature angle. A feature angle of zero will cause all element edges to
be displayed.
You may move the slider by clicking and holding the left mouse button
when the cursor is over the slider knob. While you are depressing the
mouse button, you may drag the knob in either direction. You may also
increment and decrement these values by a value of one by clicking on
the right or left arrows (><). The current value of this angle is displayed
above the slider bar.
When you are satisfied with the angle, click on the APPLY push button.
You may close this display without changing the angle by clicking the
CANCEL push button or by selecting another ViewCAST function from

PARAMETERS
the Main Function banner.
COLOR VECTORS
COLOR VECTORS enables you to
control the appearance of vector plots.
When you select COLOR VECTORS a
sub-menu of coloring options is displayed,
as shown here, is displayed.
WHITE: the vectors will be drawn in

white if a contour option has also been selected. The length of
the vector will indicate the relative magnitude and the
orientation will show the direction.
MAGNITUDE: if vector quantities are being plotted without contours,
they can be colored by their magnitude. The color spectrum on
the right of the picture will show the correspondence between
color and magnitude.
TEMPERATURE: if fluid velocity vectors are being plotted without
contours, they can be colored according to the nodal
temperatures. This type of plot provides a great deal of visual
information.
PRESSURE: if fluid velocity vectors are being plotted without
contours, they can be colored according to the nodal pressures.
These menu options are mutually exclusive. The checkbox for the
option selected will be highlighted.
You may close this display by selecting another ViewCAST function

from the Main Funtion banner.
ALL VECTORS
ALL VECTORS is a toggle switch which toggles between ALL
VECTORS and SURFACE VECTORS. When the ALL VECTORS
option is active, the vectors are drawn from every node in the active
materials of the problem. When the SURFACE VECTORS option is
active, vectors are only drawn from the nodes on the visible surface of
the mesh.

PARAMETERS
ROTATIONAL SYM
ROTATIONAL SYM provides the capability for you to display an image
of the full geometry of an object which
you may have modeled using the
rotational symmetry option. When you
select this menu option, the list and
dialog input box, shown here, will be
displayed.
ROTATIONAL SYM may be activated

by toggling the first push button in the
list to the ON position. The background
of the ROTATIONAL SYM menu item
will be highlighted in blue as a
reminder.
the following:
SECTORS--you enter the number of times the piece is repeated
around the axis of symmetry, counting the original piece as 1.
DELETED SECTORS--allows you to obtain a view with a pie-shaped
cutout by entering some number greater than 0. This number
should be less than that given for SECTORS.
X0, Y0, Z0, X1, Y1, Z1--specify the coordinates for two points that
define an axis of symmetry.
You may leave the ROTATIONAL SYM option by clicking another push

PARAMETERS
MIRROR SYM 1 and 2

MIRROR SYM provides the capability for you to display an image of the
full geometry of an object which may
have one or two planes of mirror
symmetry. Both MIRROR SYM 1 and
MIRROR SYM 2 operate in the same
way. When you select either of these
menu options, the list and dialog input
box, shown here, will be displayed.
MIRROR SYM may be activated by

toggling the first push button in the list to
the ON position. The background of an
active MIRROR SYM menu item will be
highlighted in blue as a reminder.
the X, Y, and Z coordinates for three points that define a plane of
symmetry.
You may leave the MIRROR SYM option by clicking another push
DISPLACEMENT MAG.
DISPLACEMENT MAG. provides the
capability for you to control the
magnification factor for deformations to
the mesh in stress analysis problems.
This option is only available for stress analysis problems.
When you select this menu option a dialog input box, as illustrated
here, will be displayed.
To enter a value, insert the cursor in the text input line, type the desired
value, and press ENTER. The default value is 20.Set this value to zero
if you do not wish to see the mesh deform with time.
You may leave the DISPLACEMENT MAG. option by clicking another

push button in the Main Function Banner.

PARAMETERS
PARTICLES
PARTICLES provides the capability for
you to inject a single particle into a fluid
stream. This tracer bullet allows you to
observe the path of the particle over time.
When you select this menu option, the list
and dialog input box, shown here, will be
displayed.
PARTICLES may be activated by toggling

the first push button in the list to the ON
position. The background of the
PARTICLES menu item will be
highlighted in blue when it is active.
the following:
RADIUS--specifies the radius of the particle.
DENSITY--specifies the density of the particle.
DRAG COEF--specifies the drag coefficient the particle will exhibit.
START TIME--specifies the time at which the particle will be injected
into the fluid stream.
INIT {X, Y, Z} VEL--specifies the initial velocity of the particle in each
coordinate direction.
NODE--specifies the node number where the particle is to be injected.
You may leave the PARTICLES option by clicking another push button

PARAMETERS
CUT-OFF
CUT-OFF provides the capability for you to specify a value which will
be used as the threshold for the values to be displayed. You may
designate that only values above this threshold will be displayed.
Conversely, you may designate that only values below this threshold
will be displayed. For example, the figure shown here was generated
after the criterion value was set to display only values above .6. The
figure shows the fraction solid which was above .6 at the time step this
image was captured.
When you select the CUT-OFF menu

option, the list and dialog input box,
To enter a value, insert the cursor in the

text input line, type the desired value, and
press ENTER. The value you entered will
be displayed in the VALUE line. You must indicate whether values
above or below this value are to be displayed. This is done by clicking
the rotary toggle switch which is directly above the VALUE line.
Successive clicks on this switch will result in choosing, ABOVE,
BELOW, or OFF. The default is OFF. If this option is set to ABOVE or
BELOW, the background of the CRITERION menu item will be
highlighted in blue.
You may leave the CRITERION option by clicking another push button

PARAMETERS
TITLES
TITLES provides the capability to place up to ten titles on contour and
vector plots. When you select TITLES, the window shown below is
displayed.
For each title, you need to give X and Y screen coordinates and the text
of the title to be displayed. This information is placed in the three
columns of the input window respectively. The location for the title is
measured in pixels from the top left corner of the graphics area to the
lower left corner of the text string.
You may type these coordinates manually or you can click on the X--Y
push button and use the mouse to set the location with a click of the left
mouse button.
To enter a value in the table insert the cursor in the desired input box
and type the desired value. You may enter or change any value in the
list by highlighting and retyping the entry. You may clear a table entry
by selecting the text to be deleted and pressing Delete on the keyboard.
You may clear the entire table by pressing the CLEAR push button.
Once you are satisfied with all the entries, press APPLY.
Remarks The PARAMETERS function of ViewCAST provides the capability to

tailor the view of results obtained from ProCAST. It is important to note
that these parameters do not change the geometry, simulation
description, or any of the results data. These parameters do affect what
you will see and how it will be displayed when you activate the VIEW
component of ViewCAST.
Related Topics

VIEW
VIEW
Description VIEW is a push button in the Main Function Banner. This function of
ViewCAST displays contour and vector plots. The options in this menu
enable you to manipulate the graphical output which is displayed in
order to facilitate your analysis.
The functions available from this menu will be discussed in this section.
Method VIEW is activated by clicking on it. When VIEW is activated, the

geometry will be displayed in the graphics
display window and the menu, shown
here, will be displayed on the right side of
the window.
The ROTATE, ZOOM, CENTER, DRAG,

HIDDEN, and RESTORE capabilities are
described in the VIEWING TOOLS
section of this manual and will not be
repeated here.
When you select a function from this

menu, depending upon the specific
option, ViewCAST may display additional
dialog boxes, option lists, data input
windows, or sub-menus. These graphical
interface tools will guide you through the
use of the selected option.
You may leave the VIEW function by

clicking another push button in the Main Function Banner. Each of the
VIEW menu items which are not described in the VIEWING TOOLS
section of this manual will be discussed immediately below.
PICTURE
This menu option begins the contour and/or vector plotting process.
The plot will be displayed based upon the contour or vector you have
chosen and the parameters you set. Plotting will begin at the time step
you specified and will be redrawn at the interval you specified in the
STEPS menu of ViewCAST. The figures in this section of the manual
are examples of the plots which are displayed as a result of selecting
the PICTURE menu option.
Once you have activated the picture function, you may click on the
PAUSE push button in the Main Function Banner to stop the plotting
process.
XYZ PLANES

VIEW
This tool allows you to designate specific X, Y, and Z planes in the

model for viewing.
Viewing these cross-
sectional planes is a
three step process:
1. Defining the
planes:
When you
select the
XYZ PLANES option from the VIEW menu an input box will be
opened, as shown here. You define the plane(s) of interest by
moving the slider buttons in the input box. As you move a
slider button, ViewCAST will display a reference outline in the
model. This allows you to position the plane in the area of
interest. You may set a single plane or multiple planes in any
or all of the X, Y, or Z axes. ViewCAST indicates that a plane
has been defined by placing a small arrow head above the
slider bar for the appropriate axis. As shown in the figure
above, four planes have been defined along the X axis, and two
planes have been defined along the Y and Z axes.
2. Activating the plane(s) to be shown: You may activate the planes
along each or all of the axes for viewing by selecting the X, Y,
or Z push buttons which are shown on the left-side of the input
box. When you select these push buttons, the background will
change to red., and
3. Viewing the PICTURE: After a plane has been defined and the
desired axis has been activated, click on the PICTURE push
button in the VIEW menu to display the desired cross-section.
XYZ PLANE settings may be stored

for future use by clicking the STORE
push button in the input box. This will
open an input box as shown here.
Enter the file name to be given to this
set of cross sections and click on the
APPLY push button.
Once you have saved a cross-section definition, you may READ it for
subsequent viewing and analysis. When you click on the READ push
button as shown in the figure above, an input box will open for you to
enter the name of the cross-sectional definition to be read.
The CLEAR push button in the input dialog box shown above, will clear
all planes which may have been specified and resets the X, Y, and Z
push buttons to the off position.

VIEW
The figure shown here illustrates that four cross-sections have been
designated and subsequently displayed when the PICTURE menu

option of ViewCAST was selected.
ANYPLANE PLANE
This tool allows you to define cross-sectional planes by selecting three
points in the model. Viewing these
cross-sectional planes is a three step
process:
1. Defining the planes: When you
select the ANYPLANE option
from the VIEW menu an
input box will be opened, as
shown here. You define a
plane by moving the cursor to
each of three points in the
model which define the plane
of interest. Clicking the left
mouse button will select a
point in the model and
highlight this point with a
small + sign. When three
points have been designated,
an outline of the defined
plane will be highlighted in the model. This is illustrated in the
figure below.
You may define more than one plane by clicking the NEW push button
in the input box and selecting three points in the model.

VIEW
2. Activating the plane to be shown: You may activate a defined

cross-section for viewing by selecting the desired plane
definition in the input box and clicking the OFF/ON toggle
switch in the input box. Once you have selected an entry in this
list, it will be highlighted with a red background. Note: It may
be easier for you to select specific nodes by clicking the
HIDDEN menu item in the VIEW menu.
3. Viewing the PICTURE: After a plane has been defined and
activated, click on the PICTURE push button in the VIEW menu
to display the desired cross-section.
ANYPLANE settings may be stored for future use by clicking the

STORE push button in the input box. This will open an input box
similar to that shown for the XYZ PLANES function. Enter the name to
be given to this set of cross sections and click on the APPLY push
button.
Once you have saved a cross-section definition, you may READ it for
subsequent viewing and analysis. When you click on the READ push
button as shown in the figure above, an input box will open for you to
enter the name of the cross-sectional definition to be read.
The DEL push button in the input dialog box shown above, will delete
the plane definition which has been highlighted in the list.
You may close the ANYPLANE list by clicking the QUIT push button.
The figure shown here illustrates a the result of using ANYPLANE to
define and subsequently display a cross-section. You may alternate

between the ANYPLANE input list and the PICTURE menu option to
view alternative cross-sections.

VIEW
ISOSURFACE
This tool allows you to watch the progress of the mush zone during
casting fill. To view an isosurface
you must define the upper and lower
values to be used as the limits for the
view. Once these limits are set, you
must then click on the PICTURE
option in the VIEW menu.
When you click on the ISOSURFACE

push button in the VIEW menu an
input box will be opened, as shown here. You define the limits of the
mushy zone by highlighting VAL1, placing the cursor in the Edit Value
input line, typing the desired value and pressing ENTER. You repeat this
process for VAL2. These actions will place the entered values in the
respective positions in the input box. When you have entered both of
these limits, click on the DONE push button to close the display.
Once these limits have been entered, you may click on the PICTURE
option in the VIEW menu to observe the progress of the specified
mushy zone in the casting. The example shown here illustrates the
mushy zone. Notice that (according to the limits specified in this
example) solidification has already begun in portions of the casting as
seen in the extreme right side and bottom of the casting.
DISPLACEMENT
This option is only available for stress analysis problems. It allows you
to view the deformed mesh in red superimposed on the original mesh
which is displayed in white.
REDRAW
This option redraws the image in the graphics display window. This is
useful for refreshing the graphics area.

VIEW
1 VIEW
This option is a rotary toggle button which allows you to specify 1, 2, or
4 views of the model for concurrent display. You may describe up to
four different views of the model and the respective XYZ PLANES to be
displayed for each view.
Viewing multiple views of the model is a three step process:

1. Defining the views: To describe a view, press 1, 2, 3, or 4 on the
keyboard. You will see the view number, which is displayed in
the lower left-hand corner of the work window will change to
correspond with the number you pressed.
You may rotate or reposition the model to suit your needs. You
may then specify the cross-sectional planes to be plotted for
this view. Concurrent views two through four may be defined in
the same manner by first pressing the appropriate number on
the keyboard.
2. Activating the number of concurrent views to be displayed: Click on

the 1 VIEW push button in the VIEW menu to select the desired
number of concurrent views to be displayed. Successive clicks
on this push button will cycle through the number of views.
3. Viewing the PICTURE: After the views have been defined and
activated, click on the PICTURE push button in the VIEW menu
to plot the displays.
As shown here, the work window is divided in quadrants, in this

example four, to show the views which were defined.

VIEW
REPLAY
This option allows you to load and replay a picture file. When you
select this menu option, a file name input
box is displayed. As shown here, you
place the cursor in the input line, type the
file name, and click on DONE. This will
result in the immediate action to load and
play the replay file.
You may close the file name input box by clicking the QUIT push
button.
Remarks The VIEW options of ViewCAST afford a variety of analytical tools for
visualizing the results of your ProCAST simulation. It is important to
note that you may move back and forth between the options of the
VIEW menu as well as the STEPS, MATERIALS, and PARAMETERS
functions of ViewCAST.
ViewCAST makes it easy to change starting times, time step values,

the materials to be displayed, cross-sections, as well as other attributes
of the results to be displayed. For example, clicking on any ViewCAST
menu bar push button during the PICTURE display, will stop the picture
and open the selected menu. Once you have completed the desired
change, you can restart the display activity by clicking on the VIEW
push button and then click on the PICTURE menu entry.
Related Topics PAUSE, CONTOUR, VECTOR, STEPS, PARAMETERS, MATERIALS

PAUSE
PAUSE
Description PAUSE is a push button in the Main Function Banner which suspends
contour and/or vector plotting. When PAUSE is active, you may create
replay files or postscript printer files containing the views and results
which are being displayed. Plotting may be resumed by clicking
PAUSE again.
The functions available from this menu will be discussed in this section.
Method PAUSE is activated by clicking on it. When PAUSE is activated, the

option buttons, shown here, will be
displayed in the lower-right side of
the work window. These option
buttons provide the capability to
create a replay file, using the ST
option, and/or to create the postscript file, using the P option.
As shown here, when you select the ST function, a file name input box
will be displayed. To
create a replay file,
place the cursor in
the input line, type
the file name and
click on DONE. You may resume the animated display by clicking the
PAUSE push button.
You may close the file input box without entering a file name by clicking
the QUIT push button.
The P option results in the immediate action to create a postscript

printer file. Once the file has been created you may resume the
animated display by clicking the PAUSE push button.
Remarks PAUSE may be used to temporarily suspend the animated updating of

the picture.
It is not necessary to resume the animation in order to make changes to

parameters, steps, cross-sectional planes, or other capabilities
available in ViewCAST. For example, if you pause the display and
decide to change the interval step value, you may click on the STEPS
push button in the Main Function Banner without first resuming the
picture display.
Related Topics CONTOUR, VECTOR, STEPS, PARAMETERS, MATERIALS, VIEW

USING INVERSE MODELING
CHAPTER 8
Description The Inverse Modeling module of ProCAST allows you to determine

thermophysical data or boundary conditions from simple well controlled
temperature measurements.
Method The INVERSE solver runs in a Unix session window. After you open
the session window, the INVERSE calculation can be started using the
following command at the session window prompt:
inve {prefix} [ -b ] ENTER
Prefix is a required parameter and you should enter the name of this
project.
-b is a command line option which specifies that INVERSE will be run in

the background as a batch mode task. Do not use the UNIX
ampersand (&) option to run proinve in the background.
Remarks Inverse modeling allows you to use the thermal history generated by
ProCAST as an input for deriving thermophysical properties, initial
conditions, or boundary conditions. In order to perform the selected
inverse calculations all other aspects of a problem must be set-up. This
means that information about the following components of the problem
must be defined.
geometry,
material properties,
interface heat transfers,
boundary conditions,
initial conditions, and
run parameters.
You may use menu options in the MATERIALS, INTERFACE,

BOUNDARY CONDITIONS, and RUN PARAMETERS menus to
specify the component and properties to be calculated using the inverse
methodology.
Once a problem has been configured in PreCAST, you should run

DataCAST to check the model for errors. The prefixid.dat file
generated by PreCAST contains all of the inverse settings. In a manner
similar to the PreCAST prefixd.dat file, the inverse settings file may be
modified manually with a text editor. The format of the prefixid.dat file
is described in Appendix K of this manual.
USING INVERSE MODELING, PAGE 7 - 1

Operational procedures and standards at your installation may specify

additional start-up requirements such as passwords, working directory
specifications, and project or file naming conventions. Consult your
installation or network manager for these guidelines.
There are three ways to monitor the status of the Inverse Calculation.
Monitoring the calculation is a good practice for checking to determine
that the calculation is stable and that convergence is progressing. Each
of these three methods for monitoring this progress are described here.
Using the status utility
There is a small utility program which can be run to report the status of
the INVERSE calculation. This utility may be started by opening a Unix
session window, setting the current directory to the directory containing
this problems prefix* files, and typing the following command at the
session window prompt:
statinve {prefix} ENTER
This utility prints the status of the calculation by indicating whether it is

still in progress or that it has been completed. It also provides
additional information which includes: the number of iterations already
calculated, the beta values of the last iteration, and the residual of the
current iteration.
The residual is the average temperature difference between the

measured and the calculated curves based upon an average of all the
steps and all the curves at the given iteration. The residual will
decrease towards zero and is a good way to see how the convergence
is reached.
Note: If the calculation was interrupted by the user, it will

display that the calculation is in progress.
Evolution of the beta values

The beta values obtained at each iteration are stored in the file
prefixir.dat. Accordingly, during the calculation, it is possible to use
PostCAST to visualize the evolution of each beta value from the first
iteration to the current iteration. From this plot, you can determine if
the calculation is converging. The format of the file prefixir.dat is the
same as that of the measurement. Curve I: of the file prefixir.dat
corresponds to the ith beta value.
The residual is stored as the last curve of the prefixir.dat file. You can
therefore graph the evolution of the residual as a function of the
iterations.

Comparison between the measurements and the calculated curves

The goal of inverse modeling is to find the best set of beta values with
which the calculated temperature curves will match the measured ones.
At the end of each iteration, the calculated curves corresponding to the

location of the measurement points are stored in the prefixic.dat file.
This file is updated at each iteration. You can use PostCAST to
visualize the comparison of the measured curves and the calculated
curves by superimposing one on the other. During the first iteration the
match between these two will be poor. Subsequent iterations should
improve with the match at the end of the calculation being good.
Final Results
At the end of the calculation, the final beta values correspond to the
values of the last iteration in the prefixir.dat file. The quality of the
convergence may be checked as described above and are considered
good if the beta values are not changing much during the last iterations
and if the residual is small. Note that the residual is measured in
degrees and a residual of 1" means that the average difference
between the measured and calculated curves is one degree.
Depending upon the convergence tolerance which is chosen, it is

possible that the beta values stay almost constant but oscillate around
an average value and the calculation will be continued until the
maximum number of iterations specified is reached. Based upon these
initial results, for subsequent inverse calculations, is possible to reduce
the maximum number of iterations in order to reduce the computing
time required.
If the inverse calculation is performed in a networked environment, it is

advisable to run the calculation in a directory which is on the disk
closest to the calculating CPU. This reduces the disk access delay
which may occur through the network. It is always possible to run the
calculation in the /tmp directory and then move the final results to the
home directory of the user.
Related Topics APPENDIX B, APPENDIX K, APPENDIX L
USING INVERSE MODELING, PAGE 7 - 3


INSTALLING PROCAST
APPENDIX A
INSTALLING ProCAST
Create Installation Use the Unix system command to make a directory in which you will
Directory install ProCAST. The syntax for this command is:
mkdir /directoryname ENTER
The following example creates the directory procast.
mkdir /procast ENTER
After the directory has been created, make it the active directory. The
syntax for this command is:
cd /directoryname ENTER
The following example changes to the procast directory.
cd /procast ENTER
Extract ProCAST files Mount the delivery tape and extract the files. The syntax for this
command is:
tar xvf /dev/tapeunitname ENTER
The following example extracts the files from the tape unit rst8.
tar xvf /dev/rst8 ENTER
This should create two subdirectories called BIN and LIB.
Establish Access The BIN directory must have read and execute permissions for all
Authorizations authorized users. The files in the LIB directory, the LIB directory and
the BIN directory need read and write permissions for all authorized
users. The following example changes the permission code for the files
in the BIN directory.
chmod 555 BIN/* ENTER (Gives read + execute)
The following example changes the permission code for the files in the
LIB directory.
chmod 666 LIB/* ENTER (Gives read + write)
The following example changes the permission codes for the BIN and
LIB directories.
chmod 777 BIN LIB ENTER (Gives read + write +
execute)
To perform these commands, you must be the owner of the files and
directories. The superuser can use the chown command to assign the
correct ownership for these files and directories.
APPENDICES, PAGE A - 5
INSTALLING PROCAST
Modify PATH Statement The following lines should be put into the .cshrc file of each user if they
are using the C shell:
setenv ProPATH /procast/LIB
setenv ProBIN /procast/BIN
Alternatively, if the Bourne shell is being used, the following lines
should be put in the .profile file:
ProPATH=/procast/LIB
export ProPATH
ProBIN=/procast/BIN
export ProBIN
You should make sure that the path names are the same as the
installation directory.
Establish PATH The path /procast/BIN needs to be in the set path command in either
the .login or .cshrc files of all users or in the PATH command in the
.profile file. You should make sure that the path names are the same
as the installation directory.
Unlock ProCAST To unlock ProCAST, set the ProPATH environment variable, run the
unlocking program, and supply the unique unlock code.
The syntax for this command is as follows:

pro_enable unlockcode ENTER
The unlock code will be provided to you by UES Software and it is

calculated for your unique environment.
PAGE A - 6 PROCAST USERS MANUAL

PROCAST FILE USAGE
APPENDIX B
ProCAST FILE USAGE
This appendix presents a profile of the file usage for each component of ProCAST. Presented in tabular
form, the name of the ProCAST component is displayed in the top of each table. Input files are listed in
column one. The file description for the input file is presented in column two. Output files are listed in
column three. File descriptions for the output files are presented in column four if they are different than
the descriptions of the input files.
The file usage for each ProCAST component are shown below.
PreCAST
Input Files Description Output Files Description
prefix.out PATRAN or ANVIL neutral file which describes the model prefixd.dat Problem description file
geometry
prefix.unv IDEAS universal file which describes the model geometry prefixp.dat Problem run file
prefix.ans ANSYS node and element files pre.err Error log file
prefix.14 ANSYS node and element files
prefix.15 ANSYS node and element files
pre.scr Menu descriptions for PreCAST
pre.edf Editor descriptions for PreCAST
promat.db ProCAST supplied material properties database
matl.db User's material properties database matl.db
matl.idx Users material properties index matl.idx
micro.db Micromodel material properties database micro.db
micro.idx Micromodel material properties index micro.idx
intf.db Interface heat transfer coefficients database intf.db
intf.idx Interface heat transfer coefficients index intf.idx
bndry.db Boundary conditions database bndry.db
bndry.idx Boundary conditions index bndry.idx
encl.db Enclosure properties database encl.db
encl.idx Enclosure properties index encl.idx
stress.db Stress material properties database stress.db
stress.idx Stress material properties index stress.idx
DataCAST
prefixd.dat Problem description file
APPENDICES, PAGE B - 1
PROCAST FILE USAGE
DataCAST
prefixd.out Printed output from DataCAST
prefixg.unf Unformatted geometry file
prefixd.unf Unformatted time step file
prefixt.unf Unformatted temperature file
prefixu.unf Unformatted u---velocity file
prefixv.unf Unformatted v---velocity file
prefixw.unf Unformatted w---velocity file
prefixp.unf Unformatted pressure file
prefixk.unf Unformatted turbulent kinetic energy file
prefixe.unf Unformatted turbulent dissipation rate file
prefixf.unf Unformatted fluid fraction file
prefixq.unf Unformatted heat flux file
prefixo.unf Unformatted file of nodal coordinate offsets for enclosure

elements
prefixs.unf Unformatted file of nodal coordinate offsets for moving

solid elements
ProCAST
prefixp.dat Run parameters
prefix.unf Unformatted files, where =g, d, t, u, v, w, p, f, k, e, q, o, s prefix.unf

as in DataCAST
prefix.ctoc Unformatted radiation view factor information prefix.ctoc
prefix.fic Fictitious mold information prefix.fic
prefix.sel Highest filled element when FREESF = 2 prefix.sel
prefix.fom Lost foam information prefix.fom
prefixa.unf Unformatted freezing time file prefixa.unf
prefixb.unf Unformatted dissolved gas bubble file prefixb.unf
prefixc.unf Unformatted macro porosity file prefixc.unf
prefixfs.unf Unformatted fraction solid file prefixfs.unf
prefixr.unf Unformatted compressible density file prefixr.unf
prefixn.unf Unformatted non-Newtonian shear rate and viscosity file prefixn.unf
prefixv.unf Unformatted turbulent viscosity file prefixtv.unf
prefixeng.unf Unformated electric potential file prefixeng.unf
prefixmg.unf Unformatted magnetic potential file prefixmg.unf
PAGE B - 2 PROCAST USERS MANUAL

PROCAST FILE USAGE
ProCAST
prefixx.unf Unformatted x displacement file prefixx.unf
prefixy.unf Unformatted y displacement file prefixy.unf
prefixz.unf Unformatted z displacement file prefixz.unf
prefixgs.unf Unformatted stress file prefixgs.unf
prefixgn.unf Unformatted effective plastic strain file prefixgn.unf
prefixst.unf Unformatted total load file prefixst.unf
prefixsr.unf Unformatted stress source term file prefixsr.unf
prefixcp.unf Unformatted contact pressure file prefixcp.unf
prefixp.out Printed output from

ProCAST
prefix.serr Row sum error view factor

file
prefix.view Group to group view factor

file
prefix.vf Face to face view factor file
PostCAST
prefix.unf Unformatted files, where = g, d,

t, u, v, w, p, f, q as in DataCAST
post.scr Screen descriptions for

PostCAST
post.edf Editor descriptions for

PostCAST
prefix.serr Row sum error file
prefixe.ntl Row sum error file for postprocessing use
prefixfs.unf Unformatted fraction solid file
prefixg.ntl Geometry neutral file for postprocessing use
prefixi.ntl Isochron results neutral file
prefixm.ntl Mapping function results neutral file
prefixm.unf Mapping function results unformatted file
prefixl.ntl Feeding length results neutral file
prefixl.unf Feeding length results unformatted file
prefixr.ntl Radiation model geometry file for model check-out
prefix.ntl Dependent variable results neutral file, where = t, u, v,

w, p, q
prefixi.log Temperature log
PROCAST FILE USAGE
PostCAST
prefixm.log Mapping function log
prefixl.log Feeding length log
prefix.log Analysis time log for use with dependent variable results
neutral files, where = t, u, v, w, p, q
post.err
prefix.tt Temperature, velocity, pressure, or fraction solid versus

time file
ViewCAST
prefix.unf Unformatted files, where = g, d, t, u, v, w, p, f, q as in

DataCAST
view.scr Screen descriptions for ViewCAST
view.edf Editor descriptions for ViewCAST
prefixi.ntl Isochron results neutral file
prefixm.ntl Mapping function results neutral file
prefixi.log Temperature log for use with the isochron neutral file
prefixm.log Mapping function log for use with the mapper neutral file
prefix.serr Row sum error file
prefix.view Group to group view factor file
view.color Color spectrum file ( contains RGB values ) view.color
prefix.unf Unformatted files, where = a, b, c, r, n, tv, mg, x, y, z, gs,

gn, as in ProCAST
INVERSE
prefixd.dat Problem description file
prefixim.dat Contains the node numbers or node

coordinates corresponding to the
location of the measurement points.
prefixid.dat Contains the inverse settings.
prefixir.dat Contains the evolutions of the beta values along the

iterations. It also contains the evolution of the
residual.
prefix.stat Contains information on the status of the inverse

calculation.

PROCAST FILE USAGE
INVERSE
prefixic.dat Contains the calculated temperature evolutions (of

the last calculated iteration) corresponding to the
locations of the measured curves.
prefix.list This file is created, if the inverse calculation is

performed in the background, to store the printout
which normally appears on the workstation screen.
This file is only written when the workstation buffer is
unloaded.
PROCAST FILE USAGE

MATHEMATICAL FORMULATIONS
APPENDIX C
Section 1: Energy Equations
1. Transient linear
'cp T / [ k / T ] q ( x )
0 C.1.1
t
where
T = vector of nodal temperatures
q(x) = spatially varying volumetric heat source
/
C.1.2
x y z
in Cartesian coordinates
' = constant density
cp = constant specific heat
t = time
k = constant conductivity
2. Transient non-linear conduction
' H T / [ k / T ] q(x)
0 C.1.3
T t
where
' = '0 f(T), constant or temperature dependent density
k = k0 f(T), constant or temperature dependent conductivity
H = enthalpy, a function of temperature, which encompasses the effects of specific
and latent heat
T
H( T )
cp d - L[ 1 f s (T )] C.1.4
P
L = latent heat
fs = fraction solidified
3. Transient laminar advection-diffusion
APPENDICES, PAGE C - 1
' 0H 'ui 0H /( k / T) q
0 C.1.5
0t 0xi
where
ui = fl ui,liq = component of superficial velocity
fl = fraction liquid
ui,liq = actual liquid velocity
4. Transient turbulent advection-diffusion
' 0H 'ui 0H /
T
k /T q
0 C.1.6
0t 0xi )T
where
T = eddy viscosity
)T = turbulent Prandtl number
Section 2: Continuity Equation
Conservation of mass is enforced through the continuity equation:
0' 0( 'ui )
0
C.2.1
0t 0xi
Section 3: Momentum Equations
The full Navier-Stokes equations are given by:
0( 'ui )
0 (uj 'ui p ij )ij )
'gi C.3.1
0t 0xj
where
)ij = Stokes viscous stress tensor including the Reynolds stress approximation and
assuming the bulk viscosity is negligible
0ui 0uj 0u 0u
)ij
2 k ij T i C.3.2
0xj 0xi 3 0xk 0xj
ij = Kronecker delta
p = pressure
gi = gravitational acceleration
Expanding the differentials on the advection term and using the continuity equation to simplify
yields:
PAGE C - 2 PROCAST USERS MANUAL

0ui 0u
' ' uj i 0 ( p ij )ij )
'gi C.3.3
0t 0xj 0xj
Assuming that the spatial derivatives of viscosity are small and that the fluid is nearly
incompressible, many terms in the viscous stress tensor can be neglected. A source term is
added to the standard momentum equation to simulate the effect of flow in mushy regions and to
drive the velocities to zero when the material is fully solid. This gives the final form of the
momentum equation as used in ProCAST:
0ui 0u 0u
' 'uj i 0 p ij ( T) i
'gi ui C.3.4
0t 0xj 0xj 0xj K
where
K = permeability
The permeability is calculated using the Kozeny-Carmen equation

3
fl
K
5 Ms (1 f l )2
2
C.3.5
6
Ms
Dp
where
Ms = surface to volume ratio of solid structure
= shape factor
Dp = characteristic dimension
Assuming conically shaped dendrite arms with an average diameter of 100 microns, Ms = 600cm-
1
Section 4: Turbulent Kinetic Energy
The conservation equation for turbulent kinetic energy is given by:
0('k) u 0('k) 0 T 0k

TG ' C.4.1
0t j
0x j 0xj )k 0xj
where
1
k
(u 12 v 12 w 12 )
2
u 1 ,v 1 ,w 1
fluctuating velocity components
)k
Prandtl number of turbulent kinetic energy, typically set to 1.0
0ui 0uj 0ui
G

turbulence generation rate
0xj 0xi 0xj

turbulence dissipation rate
Section 5: Turbulence Dissipation Rate
The differential equation for calculating the dissipation rate is as follows:
0(') u 0(') 0 T 0
(C G C ')
C.5.1
0t j
0xj 0xj ) 0xj k
1 T 2
where
) = Prandtl number for turbulence dissipation rate, typically set to 1.3.
Default values are: C1 = 1.44 and C2 = 1.92
Section 6: Eddy Viscosity
The turbulent eddy viscosity is calculated from the turbulent kinetic energy and dissipation rate as
follows:
C 'k 2
T
C.6.1

where
C = 0.09 is a default
Section 7: Non-Newtonian
With non-Newtonian flow, the shear stress is a nonlinear function of the strain rate, represented by
-
C.7.1

The current version of ProCAST contains an implementation of the Carreau-Yasuda correlation in which
the viscosity is given by
n 1

(0 )[1 ( )a ] a C.7.2
where
0 = zero strain rate viscosity
= infinite strain rate viscosity
= phase shift coefficient
a = Yasuda coefficient
n = power law coefficient
In ProCAST, all five of these coefficients can be constants or functions of temperature.
The strain rate, as it appears in the correlation, is taken to be the magnitude of the strain rate
tensor:
.5 .5

1
ij ji
1 ( : C.7.3
2 2
M M
i j
where
0u 0u 0v 0u 0w 0u
0x 0x 0x 0y 0x 0z
. 0u 0v 0v 0v 0w 0v C.7.4
0y 0x 0y 0y 0y 0z
0u 0w 0v 0w 0w 0w
0z 0x 0z 0y 0z 0z
The shear force terms in the momentum equations take on the following form:
X :
0 (- ) 0 (- ) 0 (- )
0x xx 0y yx 0z zx
Y :
0 (- ) 0 (- ) 0 (- )
C.7.5
0x xy 0y yy 0z zy
Z :
0 (- ) 0 (- ) 0 (- )
0x xz 0y yz 0z zz
Using the x-momentum term as an example and the stress-strain relationship shown previously, the
following expansion is possible:
0 0u 0u 0 0v 0u 0 0w 0u
0x 0x 0x 0y 0x 0y 0z 0x 0z
0 0u 0 0u 0 0u
C.7.6
0x 0x 0y 0y 0z 0z
0 0u 0 0v 0 0w
0x 0x 0y 0x 0z 0x
The first three terms on the right hand side are the same as appear in the Newtonian
Navier-Stokes formulation. The last three terms can be simplified somewhat by expanding them
further:
0 0u 0 0v 0 0w
0x 0x 0y 0x 0z 0x
C.7.7
0 0u 0v 0w 0u 0 0v 0 0w 0
0x 0x 0y 0z 0x 0x 0x 0y 0x 0z
Assuming that the densification rate, 0' / 0t , is negligible, then the first term on the right hand
side vanishes from continuity. This leaves a non-Newtonian contribution to the shear force of
the form:

/x V # / C.7.8
Similar terms arise for the y and z momentum equations as well.
A dissipation term is also added to the energy equation of the form:
0
2 0u 0v 0w
2 2 2

0x 0y 0z
C.7.9
0v 0u 2
0u 0w
2
0v 0w
2
0x 0y 0z 0x 0z 0y

Section 8: Initial and Boundary Conditions
1. Initial conditions
T (x,0)
T0 (x)
u (x,0)
u0 (x)
v (x,0)
v0 (x) C.8.1
w (x,0)
w0 (x)
p (x,0)
p0 (x)
2. Fixed temperature boundary condition
T (x)
T d (x) f (t), on
1 C.8.2
where

1 = some subset of the total boundary
Td(x) = specified temperature vector
f(T) = time function
This is also known as a Dirichlet boundary condition. In a steady state problem, there is no time
function modifying the specified temperatures.
3. Fixed velocity boundary condition
V (x)
Vd (x) f (t), on
1 C.8.3
where
Vd(x) = specified velocity vector
f(t) = time function
4. Fixed pressure boundary condition
P (x)
Pd (x) f (t), on
1 C.8.4
where
Pd(x) = specified pressure vector
5. Fixed turbulent kinetic energy boundary condition
(x)
d (x) f (t), on
1 C.8.5
where
d(x) =
specified turbulent kinetic energy vector
f(t) = time function
By default, the turbulent kinetic energy is taken as 5% of the total kinetic energy of the flow, that
is

1
(.05V )2 C.8.6
2
where
V = total velocity magnitude
6. Fixed turbulent dissipation rate boundary condition
(x)
d (x) f (t), on
1 C.8.7
where
d(x) =
specified turbulent dissipation rate vector
By default, the turbulent dissipation rate is calculated as
3

c 2 / C.8.8
where
= a characteristic length which is assumed to be 1.0% of the smallest dimension of
the opening
c = the run parameter CMU

7. Specified heat flux boundary condition
k / T # n
qn f (t), on
2 C.8.9
where
qn
specified heat flux
n
unit vector normal to the surface

2
some subset of the total boundary
This is also known as a Neumann boundary condition.
8. Convective heat flux boundary condition
k / T # n
h f (t) g (T ) [T Ta], on
2 C.8.10
where
h = convection (film) coefficient
g(T) = temperature function
Ta = ambient temperature, which can be a function of time.
9. Radiation heat flux boundary condition
k / T # n
) g (T ) [T 2 Ta2 ] [T Ta ] [T Ta ], on
2 C.8.11
where
)= Stefan-Boltzman constant
= emissivity
This is the "simple" radiation model in which it is assumed that there is only one ambient
temperature present. Thus, the view factor is equal to one.
Section 9: The View Factor Radiation Model
For the more complex view factor radiation capability, ProCAST uses a net flux model. Rather than
tracking the reflected radiant energy from surface to surface, an overall energy balance for each
participating surface is considered.
At a particular surface i, the radiant energy being received is denoted qin, i. The outgoing flux is qout, i.
The net radiative heat flux is the difference of these two.
qnet, i
qout, i qin, i C.9.1
Utilizing the diffuse, grey-body approximation, the outgoing radiant energy can be expressed as
qout, i
) i Ti4 (1 i ) qin, i C.9.2
The first term in (C.9.2) represents the radiant energy which comes from direct emission. The second
term is the portion of the incoming radiant energy which is being reflected by surface i.
The incoming radiant energy is a combination of the outgoing radiant energy from all participating
surfaces being intercepted by surface i. Specifically, the view factor Fi-j is the fraction of the radiant
energy leaving surface j which impinges on surface i. Thus,
N
qin, i
M
Fi j qout, j C.9.3
j
1
where
N = total number of surfaces participating in the radiation model and the view factors
are calculated from the following integral.
1 cos j cos i
Fi j
d Ai d Aj
Ai %r 2 C.9.4
Aj Ai
where
Ai = area of surface i
i = polar angle between the normal to surface i and the line between i and j
r = magnitude of the vector between surfaces i and j
Traditionally, (C.9.4) is evaluated by numerical integration, either in the form shown or converted
into an equivalent line integral. In ProCAST, the view factors are computed using a proprietary
technique.

Solving (C.9.2) for qin, i yields:
qin, i
1
[qout, i ) i Ti4 ]
1 i C.9.5
Combining (C.9.5) with (C.9.3) gives a relationship involving the outgoing radiant fluxes only.
These outgoing fluxes are known as radiosities. The final form is
N
M
[ ij (1 i ) Fi j ] qout, j
)i Ti4 C.9.6
j
1
The Kronecker delta, i,j, has been included to incorporate the diagonal term. Since there are
equations of the form (C.9.6), a simultaneous solution is required for a large non-symmetric
system. Because of the reciprocity relation, Ai Fi-j = Aj Fj-i (C.9.6) can be transformed into a
symmetric form which is more economical to solve. Multiplying (C.9.6) by
Ai
C.9.7
(1 i )
yields:
N Ai i Ai
ij Ai Fi j qout, j
) Ti4 C.9.8
M
j
1 (1 i ) (1 i )
which is solved for the vector of radiosities, qout, j. The net radiant flux is obtained by combining
(C.9.1) and (C.9.5), giving
i
qnet, i
[)T i qout, i ]
4
C.9.9
1 i
This heat flux then appears as a boundary condition for the heat conduction analysis in
ProCAST.
Section 10: Finite Element Discretization
Conduction
The solution domain, 6, is divided into a set of non-overlapping subregions which completely fill the
space. In each of these elements, temperatures are interpolated from values at discrete nodal locations.
This yields a temperature field which approximates the exact solution.

T ( x, t )
Ni (x) T i (t) C.10.1
where
Ni = interpolating or "shape" functions
Ti = nodal values of temperature
Repeated indices in a term indicate the application of the Einstein summation convention. The particular
shape functions employed are a consequence of the element types. Currently, ProCAST supports linear
brick, tetrahedral, and wedge elements and quadratic tetrahedral elements.
The following development will concentrate on the non-linear, transient heat conduction case. Inserting
the approximate solution (C.10.1) into the governing field and boundary condition equations (C.1.3),
(C.8.9--C.8.11), produces a residual error. This error is minimized in an average sense by the Method of
Weighted Residuals, applying the Galerkin procedure of using the shape functions, Ni, as the weighting
functions. This results in the symmetric matrix system
C T K T
F C.10.2
where
C = capacitance matrix with terms
Cij
' dH Ni Nj d 6 C.10.3
dT
6
K = conductivity matrix with terms
Kij
/ N i # (k / N j ) d 6 h Ni Nj d
2
C.10.4
6
2
F = source vector with terms
Fi
Ni (q hT a ) d
2
C.10.5

2
T
time derivative of the vector of nodal temperatures
In (C.10.4) and (C.10.5), h combines the effects of Newtonian and radiation heat transfer.

The integrations are performed on an element-by-element basis and assembled to form the global
matrices. Typically, these integrations are too complex to perform analytically. Recourse is taken to
numerical integration techniques, which involve an isoparametric mapping to a local, element-based
coordinate system. Details of this approach can be found in any standard finite element text book.
One feature of ProCAST which particularly enhances its utility for casting simulations is a coincident
node technique for handling the mold-metal interface and parting surfaces. Along the desired thermal
break interface,
3, a second set of spatially coincident nodes is added to the original nodal topology.
The original nodes would be assigned to the elements on one side of the interface, the metal for
example, and the second set to the other side. A Newtonian heat flux relation between the two sets is
incorporated into the conductivity matrix by an integration on
3,
Nk d
3
1
K
K hc Ni Nj
2 C.10.6

3
where hc coincident interface heat transfer coefficient. This may be a function of time and/or
temperature. Node k is coincident to node j.
The advantages of using coincident nodes rather than thin elements at the interface are that it is more
economical in terms of CPU time, and it is easier to specify when using commercial preprocessing
packages to create the finite element mesh. In ProCAST, this technique will automatically be employed
at the interface of dissimilar materials if the user desires.
Momentum
Applying Galerkin's method to the momentum equation gives the following expression:
Ni
' N 0uj dV Ni
' uk
0uj
dV Ni
0 1 0(Nj uj) dV
fl
j
0t fl
2 0xk 0x k f l 0x k
C.10.7
Ni 'gj dV
0p
Ni dV Ni
1
Nj uj dV
0x K
where
1 = ( + T)
A streamline upwind approximation is used in the advection term:
' 0(Nj uj) ' u 0u

Ni uk dV Ni dV C.10.8
2
fl 0xk fl
2 s 0s
where
us = streamline velocity
s = streamline coordinate
The divergence theorem is applied to the diffusion term of the momentum equation so that the weighting
functions and interpolating functions will be of the same order.
Ni
0 1 0(Nj uj ) dV
0Ni 1 0Nj
u dV Nj
0(Nj uj) 1
# ndS C.10.9
0xk fl 0xk 0xk fl 0xk j 0xk fl
The final discretized momentum equation has the form:
Mu (D A C )u Sg Sp
0 C.10.10
where
Mij
' N N dV
i j
fl
1 0Ni 0Nj
Dij
dV
f l 0xk 0xk
's 1
Aii
us Ni dV
fl
2 s P
C.10.11
1
Cij
Ni Nj dV
K
Sg, i
Ni 'gk dV
P
Sp , i
Ni
0p dV
0xk

Using a two level time stepping method and solving for a correction value yields the following equation
form:
(u n 1 u n )
M ( D A C ) [u n 1 (1 )u n ] Sg Sp
0
t
(M/t)u n 1 ( D A C ) u n 1
(M/t)u n ( D A C ) (1 )u n Sg Sp C.10.12
[(M/t) ( D A C ) ] u n 1
( D A C )u n Sg Sp
Pressure
If the discretized momentum equations are considered in terms of the resulting coefficients, Bij, and
nodal velocities, uj, then the effect of pressure gradients may be separated out as:
Bii ui
Bij uj f i
0p dV
Ni
M
0x
ui
u
1
Ni
0p dV
u K 0p
C.10.13
Bii 0x i
0x
Bij uj f i Ni dV
u
M
, Ki
P
Bii Bii
It has been assumed momentarily that the pressure gradient is constant under the integral. First, the
continuity equation is discretized using Galerkin's method of weighted residuals and Green's Lemma:
Ni
0' 0('uk ) dV
0t 0xk
C.10.14
0' dV 0Ni
Ni Ni ( 'uk ) # n dS 'uk dV
0
0t 0xk
Substituting the velocity correction relation above into the discretized continuity equation yields the
pressure equation:
' uk Kk
0p 0Ni dV
Ni ('uk ) # n dS Ni
0' dV
0xk 0xk 0t
C.10.15
0N 0N 0' dV
'Kk 0p i dV
' uk i dV Ni ('uk) # n dS Ni
0xk 0xk 0xk 0t
This is solved in a correction form as:
D p n 1
D p n Su S' C.10.16
where:
0Ni 0Nj
Dij
'Kk dV
0xk 0xk
0Ni
Su, i
'uk dV
0xk
C.10.17
Ss, i
Ni ( 'uk ) # n dS
Sp, i
Ni
0' dV
0t
Section 11: Time Stepping Algorithm
The first order differential equation system which is obtained from the finite element spatial
discretization, (C.10.2), is numerically integrated by a two level predictor-corrector scheme.
Predictor Step
[C t K ] T0n 1
[C t (1 ) K ]T n F C.11.1
where
C, K, and F are evaluated with intermediate temperature values at time level n

n1
T0
predicted temperature vector
t
current time step
Corrector Step
[C t K ] Tpn 1
[C t (1 ) K ]T n F C.11.2
where
C, K, and F are evaluated with intermediate temperature values T~

T~
T p (1 ) T n , [0.0,1.0]
n1
n1
Tp
corrected temperature vector

The solution vector is corrected until either the maximum of number of corrections is reached or the
maximum difference in temperatures between two successive iterations is less than a user-specified
convergence criterion. This algorithm automatically adjusts the time step according to the number of
corrector iterations that were required on the previous step. If the maximum number of corrections is
exceeded, the time step is reduced and the step attempted again.
The value of , selected from the range of 0.0 to 1.0, determines the nature of the algorithm. Some
familiar two-level schemes which may be recovered are as follows:

0.0, forward difference, explicit

1
, central difference
2

2 , Galerkin
3

1.0, backward difference, fully implicit
If capacitance matrix is lumped with the forward difference scheme, the global system matrix becomes
diagonal and is therefore rapidly inverted. However, the time step restriction to ensure stability can be
unacceptably severe. For unconditional stability, it is required that 1 .
2
The central difference scheme is the only two-level method with second order accuracy and is thus
recommended in general. However, it also has a time step restriction to prevent oscillation. The time
step is governed by the eigenvalue spectrum of the system matrix. In a typical casting simulation, the
high frequency modes, which correspond to large eigenvalues, quickly decrease in amplitude. This
permits a gradual increase in the time step from a small initial value without producing oscillations.
The backward difference scheme has no stability or oscillatory time step restriction and is therefore
always "safe." However, it is only first order accurate and tends to smooth out results which should be
sharply varying.
An Implicit-Explicit Algorithm is available, based on this two-level scheme. It is implemented simply by

assigning values of independently to each element. For = 0.0, the element capacitance matrix is
lumped, contributing only diagonal terms to the system matrix. This speeds up the solution of the system
when a profile based solver is used. In casting simulations, it is often possible to treat the mold elements
explicitly because of the large difference in material properties between metal and mold. A substantial
reduction in computational costs can be realized if this technique is employed.
Section 12: Electromagnetics
We start with Maxwell's Equations:
/ H
J 0D C.12.1
0t
/ E
0B C.12.2
0t
/#B
0 C.12.3
/#D
' C.12.4
where
E = the electric field intensity
J = the current density
D = the electric flux density (displacement flux)
H = the magnetic field intensity
B = the magnetic flux density
' = the charge density
Assuming linear material properties, these additional relations are also considered:
B
H C.12.5
D
E C.12.6
J
)E C.12.7
where
= the magnetic permeability
= the permittivity
) = the electrical conductivity
For the induction heating problem, it is convenient to let the magnetic flux density be represented by the

curl of a magnetic vector potential,
B
/ A C.12.8
Therefore, Equation C.12.3 is automatically satisfied. Also, we will ignore the displacement flux, D = 0,
so Equation C.12.4 is satisfied.
Considering Equations C.12.2 and C.12.8, if E

/ 1 0A , then
0t
/ E
/ /1 / 0A
/ 0A C.12.9
0t 0t
thus satisfying Equation C.12.2. Equation C.12.1 is all that remains to be satisfied. Substituting
Equations C.12.5 and C.12.8,
/ 1
( / A)
) / 1 ) 0A
J0 e j 7 t ) 0A C.12.10
0t 0t
Assuming that A = A0 e j7t with the same frequency as the driving current, then
/ 1
( / A0 )
J0 ) j7 A0 C.12.11

Expanding the left hand side and assuming that the magnetic permeability is constant within an element
yields,
1
/ ( / A0 )
1 / ( / # A0 ) 1 / 2 A0) / 1 ( / A0)
C.12.12

1 / 2 A0

Therefore, the final equation used to determine magnetic potential is,
1 2
/ A0 ) j 7A0 J0
0 C.12.13

This is solved numerically as three systems of equations in the X, Y, and Z directions, with real and
imaginary components. Other quantities of interest can be derived from the magnetic vector potential:
Magnetic field, B
/ A
Eddy current, Je
)j7 A
Lorentz force, Fl
Je B
Eddy heating, Q e
1
)72 A 2
2
Section 13: Stress Analysis
Governing equations
div )b
0 6in
)#n
t on
) C.13.1
u
u on
u
where
) = the stress tensor
b = the body forces
n = the surface unit normal
= the surface traction
= the prescribed displacements
Thermal-Mechanical Contact
Mechanical constraint:
g (u) 0
t N (u)
n # ) # n 0 on
c C.13.2
t N (u) g (u)
0
where
g = the interface gap
tN = the normal surface traction

= the contact surface
Modification of interface heat transfer coefficient
h
1. /
1
g C.13.3
h0 kair
Variational Formulation

) # grad ( u) d 6 b # u d6 t # u d
6 6
)
P P P
C.13.4
< ! g (u)
k
> n # u d

0

c
P
where
k + 1 = k + ! g(u) the augmented Lagrangian multiplier

! = the penalty number

x = (x + x )

Finite Element Discretization
B T ) d 6 N T b d 6 N T t d
k 1N T n d

0
C.13.5
6 6
)
c
Linearization of this equation yields:
B TD B d 6 !N T
s Ns
n
u n 1
6
B T
)nd 6 N T bd 6 N T t d
Nk
s
T n C.13.6
6 6 6
un1
u n un 1
where
D** = the consistent tangent matrix described later.
Stress Calculation
Elastic
)
D ( T ) C.13.7

1
/ u ( / u)T C.13.8
2
T
(T) I T C.13.9
where
D = the elasticity matrix containing material properties (Young's modulus, E, and
Poisson ratio, )
= the thermal expansion parameter
T = the temperature change
Inelastic

e p T C.13.10
)
D ( p ) C.13.11
Flow rule
p
0f C.13.12
0)
where

the plastic flow parameter

General Form

1 ( f ) C.13.13
Yield Function ( Von Mises )
f ( ),T, )
F ( ) ) ( p, T)
0 C.13.14
F())
3
(s : s )1/2 C.13.15
2
where the deviatoric stress is given by
s
) 1
(tr)) I C.13.16
3
Linear hardening rule

H(T)
p Y0 (T ) C.13.17
where H is the linear hardening parameter, Y0 is the initial yield stress, and the effective plastic strain is
given by
t
p
2
p d - C.13.18
3
0
Power law hardening rule

( 0 p ) m C.13.19
where 0 is the initial yield strain given by

1
0
E m 1
C.13.20

is a strength parameter and m is the hardening exponent
Plasticity
1(f)
f

0 C.13.21
Visco-plasticity

1
1(f) C.13.22

where, 1/ is the viscosity and

N
1 (f )
f
C.13.23

or
f
M
1 (f )
e 1 C.13.24

Radial return mapping algorithm
Integrating Equations C.13.11 and C.13.13 by a backward Euler method,
Rn 1
n 1 D 1)n 1 n 1 0f n 1
0 C.13.25
0)
rn 1
n 1 t 1 ( f n 1 )
0 C.13.26
Solving by Newton-Raphson yields the system of simultaneous equations,
D
0f j
0) ) j
R
j

C.13.27
()
t d1 0f T
r
A
df 0)
where
i 0 f2
2
D
D 1 C.13.28
0)
t d1 0p 0
p
A
C.13.29
0()
df 0
The total stress is then updated by,
) jn11
) jn 1 ) j C.13.30
Finally, the consistent tangent matrix in Equation C.13.6 can be derived from Equation C.13.27,
1
D
D D
0f 0f T
D T A
0f T
D
0f C.13.31
0) 0) 0) 0)
Section 14: Preconditioned Conjugate Gradient Solver
The conjugate gradient method is a semi-direct scheme for finding the solution to the positive definite,
symmetric system Ax = b. It does this by building up the solution in steps by the linear combination of a
set of independent, A-conjugate basis vectors pi, called search vectors. Thus
x i
x0 1 p1 2 p2 ... i pi C.14.1
A-conjugate means that the inner product (pi, Apj) = 0, I g j . The term "semi-direct" refers to the finite
termination property, i.e., that the method is guaranteed to converge to the exact solution in N steps in
the absence of numerical round-off, where N is the degree of the matrix A. If the conjugate gradient
method actually took that many steps, it would not be competitive with Gaussian elimination solvers. Its
utility derives from the fact that a sufficiently accurate solution may be obtained in far fewer steps. In
other words, it can be used as an iterative solver. This is particularly important for the large, sparse
equation systems that occur in finite element analyses. CPU savings of up to 50% over direct solvers
are possible.
A complete development of the conjugate gradient method is rather lengthy, but we will provide a
summary of how the unconditioned scheme works for the sake of completeness.
An initial guess, x0, is chosen either from the initial condition or the result of the previous time step. The
initial residual is computed and used as the beginning search vector.
r0
b Ax0
C.14.2
p1
r0
For steps i = 1, ... N-1:
( ri 1 , ri 1 )
i
C.14.3
( pi , Api )
The formula for i is derived from the minimization of the functional
1(xi )
1
( xi , Axi ) ( b T xi ) C.14.4
2
with respect to i. This is equivalent to finding the value of which minimizes the residual error, given
the search vectors available so far.
xi
xi 1 i pi
ri
ri 1 i Api
C.14.5

These last two steps are the improvement in the estimate of the solution vector xi and the reduction in
the residual error ri. At this point, the norm of the residual error, (ri, ri), is calculated and compared with
the convergence criterion . If (ri, ri) > , continue in the loop.
( r i ,r i ) ( ri , Api )
i

( ri 1 , ri 1 ) (pi , Api ) C.14.6
pi 1
ri i pi
In the calculation of i, the first form is used in practice, but the second is perhaps more indicative of its
function. The next search vector is chosen so that it will be A-orthogonal to the previous vector, and
thereby to all prior ones. The direction of the new search vector is that of the latest residual with all
components aligned with previous search vectors subtracted out.
( ri 1 , ri 1 )
( r i , r i ) C.14.7
End of loop.
When viewed as an iterative technique, the rate of convergence of the conjugate gradient method is
governed by the condition number of the matrix A. The condition number is the ratio of the maximum
eigenvalue to the minimum. Thus, if A is the identity matrix, the condition number would be one, and the
CG solver would converge in one step. The goal of preconditioning is to transform the matrix system so
that the new coefficient matrix has a condition number close to one. A conditioning matrix P is chosen
such that
P T P
M 1 A 1 C.14.8
Pre and post-multiplying the system Ax = b by P,
( PAP T )
Pb
C.14.9
Cy
d
where
C
PAP T
y
P T C.14.10
d
Pb
Since C is similar to PTPA = M-1A, it has the same condition number. So if M-1 A-1, then C I, the
identity matrix. When the conjugate gradient method is applied to the transformed system Cy = d and
then all the equations restated in terms of the original system, some simplification occurs by defining a
new vector zi,
zi
P T Pri
M 1ri
C.14.11
Mzi
ri
So it is necessary to find a matrix M which approximates A, but is faster to invert. There are many
possibilities, but one of the best choices appears to be partial Cholesky factorization.
M
LTDL C.14.12
The sparsity pattern of the original matrix A is preserved in the factored matrix L, i.e., there is no fill-in.
This speeds up the factorization process and minimizes the storage requirements.
The Preconditioned Conjugate Gradient Algorithm can now be outlined:

As before, chose x0 and calculate r0 = b - Ax0
Factor A into M = LTDL
Solve for z0 from Mz0 = r0
Set search direction p1 = z0
For i = 1, ... N-1;
( zi 1 , ri 1 )
i
( pi , Api )
xi
xi 1 i pi (C.14.13)
ri
ri 1 i Api
zi
M 1 ri
If (zi, ri) > , continue in the loop
( zi , ri )
i
( zi 1 , ri 1 )
(C.14.14)
pi 1
zi i pi
( zi 1 , ri 1 )
( zi , ri )
End of loop

Notice that the solution of Mzi = ri takes place in each step. Therefore, each step takes considerably
longer than the unconditioned conjugate gradient algorithm. This is more than made up for by the
reduction in the number of steps required to reach convergence, typically by a factor of ten.
Section 15: Preconditioned Conjugate Residual Solver
The Preconditioned Conjugate Residual Solver is used when the system matrix is not symmetric. It is
similar to the ICCG method, but a LU decomposition is performed instead of Cholesky. The procedure
follows the following steps:
Chose an initial estimate x0 and calculate r0 = b - Ax0
Factor A into M = LU
Set search direction p1 = r0
For i = 1, ... N-1;
( ri 1 , Api )
i
( Api , Api )
xi
xi 1 i pi (C.15.1)
r i
ri 1 i Api
zi
M 1 ri
If (ri, ri) > , continue in the loop
( Azi , Api )
i
( Api , Api ) (C.15.2)

pi 1
zi i pi
End of loop
Section 16: Micromodeling
Equiaxed Dendrite Model
This model is also based on instantaneous nucleation, whereby the final grain size is known from the
nucleation model. This model is also based on 1--D spherical growth. Following nucleation, the dendrite
tip growth is controlled by the supersaturation at the dendrite tip. This means that the tip growth is based
on the total undercooling at the tip. As the tip grows, the solid fraction in each grain is not known from
the tip position. In fact, the fraction solid is less than the fraction of the grain obtained from the tip
position. At each time, the new tip concentration and fraction solid are known from a thermal and solute
balance at the scale of the grain. The tip growth velocity is obtained from the Lipton-Glicksman-Kurz
model, which simulates the growth of an isolated
dendrite tip. The tip continues to grow until it reaches
the end of the grain. At this point, solid fraction is still
grain envelope
less than unity. However, mixing of the solute is
complete at this stage. Therefore, a Scheil type
Final Grain Size
equation can be used to calculate solid fraction. If
the phase diagram has a terminal reaction, e.g.,
eutectic, the remaining liquid gets rapidly transformed
into a solid structure.
C*
Figure C-1 shows an eutectic grain and its solute C0
concentration profiles. fs is the fraction solid in the Concentration
1 2 3
grain and if the dendrite is compressed to form a solid
sphere, then the corresponding radius of the solid
would be Rs. f g is the fraction of grain enveloped by
the dendrite tip. The radius of the grain 0 fs fg 1
corresponding to f g is given by Rg. The final grain Fraction of Grain
radius is Rl, which is obtained from the nucleation
Figure C-1 Schematic representation of an equiaxed dendrite
model. grain; region 1 = solid phase; region 2 = interdendritic liquid;
region 3 = liquid.
In this figure, it may be noted that there is a boundary

layer of solute ahead of the dendrite tip. It is assumed that mixing of solute in the interdendritic region is
complete (region 2 in Figure C-1). It is also assumed that the temperature of the grain is uniform and
curvature undercooling is neglected. Also it is considered that the thermal undercooling is negligible.
The growth of the dendrite tip is controlled mainly by solute diffusion. Therefore, only solutal
undercooling is considered.

A solute balance at the scale of the grain is written as:

fs 1
kc (f s)df s c ( fg fs ) c ( f, t)df
c0 C.16.1
P P
0 fg
where, k is the partition coefficient, c*( f s) is the tip concentration as a function of fs, co is the initial solute
concentration, c( f, t ) is the concentration in the liquid region 3 as a function of fraction of grain and time.
The three terms are for solute content in the three regions of Figure C-1.
The following equation describes a thermal balance at the scale of the grain, assuming that the
temperature in the grain is uniform:
'Cp dT
'L df # 4
% Rl3
Qext # 4%Rl2 C.16.2
dt dt 3
where, ' is the density, Cp is the specific heat, L is the gravimetric latent heat of fusion, Qext is the
external heat flux of the solidifying grain.
The assumption of uniform temperature and interface equilibrium leads to the following equation:
dT

dT
m dc C.16.3
dt dt dt
where, T* is the temperature at the dendrite tip and m is the slope of the liquidus line. The incorporation
of the thermal balance equation in the solute balance equation leads to the following quadratic equation
in the dendrite tip concentration, c*:
Ac 2 Bc C
0 C.16.4
where, the coefficients A, B, and C are evaluated at every time step. The coefficients A, B, C involve
terms that include total solute content in the solid ( region 1 ) and the total solute content in the liquid
(region 3). In order to calculate the total solute content in the liquid region of the grain as well as to
obtain the concentration at the end of the grain, the diffusion equation in the liquid region needs to be
solved. This is done by assuming that the diffusion is quasi-steady in nature. Then, the diffusion
equation is solved analytically with the following boundary condition:
r
Rg , c
c C.16.5
Solution of the above quadratic equation leads to the evaluation of interface concentration at the
dendrite tip at each time step. Once the interface concentration is known, the rate of change of fraction
of solid at each time step is obtained from the thermal balance equation as given above. This is used to
calculate the heat source term in the energy balance equation at every time step.
The tip growth velocity is obtained with the Lipton-Glicksman-Kurz model which considers that growth of
the dendrite tip is controlled by solute diffusion and that thermal undercooling is neglected. This is
mostly valid for a situation where the Peclet number is low. The following equation results from this
model:
d Rg

AT2 C.16.6
dt
where T is the solutal undercooling at the dendrite tip and A is a parameter that involves solute
diffusivity in the liquid, liquidus slope, initial solute concentration, Gibbs-Thompson coefficient and the
partition coefficient.
Since nucleation starts instantaneously with zero degree undercooling, the interface concentration will
increase to drive the dendrite tip growth. The growth of the dendrite tip is rapid in the beginning because
the driving force i.e., the difference between the interface concentration and concentration at the end of
the grain, is large. Toward the end of solidification both the interface concentration and the
concentration at the end of grain increase because of solute rejection in liquid, and hence the growth rate
is slowed down.
The solute diffusion calculation is continued until the time when the dendrite tip radius becomes equal to
the grain radius. The equiaxed dendritic growth continues until the fraction of solid becomes one or
another terminal reaction takes place. If this reaction is an eutectic reaction, all the remaining liquid gets
transformed into an eutectic structure.

The secondary dendrite arm spacing parameter is obtained using the coarsening model of Feurer and
Wunderlin, which is described through the following equation:
2
M # ts
1/3
C.16.7
where 2 is secondary dendrite arm spacing, ts is the local solidification time, M is the coarsening rate
constant which can be computed with the following equation:
m
Cl

D ln
C0 C.16.8
M
m(1 k)(C0 Cl )
m
where

= Gibbs-Thompson Coefficient
D = Solute Diffusion Coefficient in Liquid Phase
Co= Initial Solute Concentration of the alloy
m = Liquidus slope
k = solute partition coefficient
Clm = final composition of solute in liquid at the end of dendrite solidification
In most cases, Clm is equal to the eutectic composition, Ce. A typical value of M for an Al-7%Si alloy is
8.8. 10-6 m . s-1/3
Coupled Eutectic Growth Models
The Coupled Eutectic Growth Models are divided into two categories:
1. Instantaneous Nucleation
2. Continuous Nucleation
These models can be applicable to both regular and irregular eutectics. In the case of regular eutectics,
growth of both phases of the eutectic structure are non-faceted in nature. For irregular eutectic, the
growth process of one of the phases is faceted. Growth of the faceting phase requires considerably
higher entropy of fusion. Examples of faceted growth are graphite growth in stable austenite/graphite
eutectic and Silicon in Al-Si eutectic. The metastable austenite/cementite eutectic is an example of
non-faceted/non-faceted type eutectic growth.
Growth of both the stable and metastable eutectic are addressed here. Growth of the stable eutectic
usually proceeds at a higher temperature. For example, the difference between the stable and
metastable eutectic temperature in cast iron is about 6 (C. This value may, however, be influenced by
the amount of alloying elements present. A higher cooling rate results in the formation of a metastable
eutectic.
These models assume bulk heterogeneous nucleation at foreign sites which are already present within
melt or intentionally added to the melt by inoculation. So these models are valid for the equiaxed region
of castings. The basic theory of heterogeneous nucleation has been described by Turnbull and Fisher.
Considering the fact that the initial nucleation site density n0 in the melt will decrease as the nucleation
proceeds ( i.e., extinction of nucleation sites ), the nucleation rate is given as:
K2
n
K1 [n0 n(t) ] exp C.16.9
T ( T )2
where K1 is proportional to the collision frequency of the atoms of the melt with the nucleation sites of the
heterogeneous particles and K2 is described as a function of the interfacial energy balance between the
nucleus, the liquid, and the foreign substrates, (t) is the nucleation density as a function of time. The
drawback of the above model is that the final grain density does not depend on solidification conditions,
which is an experimental fact.
To avert this, the instantaneous nucleation model is modified to take into account the dependance of
cooling rate on the number of nucleation sites or substrates. With an increase in cooling rate or
undercooling, the number of substrates increases which explains the existence of more grains in faster
cooled regions of a casting.
The continuous nucleation model is based in principle on Oldfield's approach, as modified by Rappaz.
The modifications lie in the use of a statistical approach. This model is described in Figure C-2.
Figure C-2 Continuous Distribution of Nucleation Sites used for modeling equiaxed
solidification

In continuous nucleation, the process starts at the nucleation temperature and proceeds until the stage
when the minimum in the cooling curve is attained. The grains which
have already nucleated grow to some extent by the time the minimum
undercooling is reached, giving a Gaussian distribution in size. By Liquid
conducting a few experiments, the mean and standard deviation of Eutectic cells
this distribution can easily be determined from simple DTA-type
experiments using liquid from a given melt. Regardless of the
nucleation process, the models assume that the grains are equiaxed
and that they grow freely in liquid as spheres until they impinge on
each other. The growth process stops when all the liquid is
consumed. Figure C-3 is a schematic representation of equiaxed
growth of eutectic grains at some intermediate stage of growth.
The growth of the grains is controlled by thermal undercooling at the

solid/liquid interface. Solutal undercooling is neglected here since
solute diffusion during eutectic solidification is negligible. The
Figure C-3 Schematic representation of
thermal undercooling is given by the difference between the eutectic equiaxed eutectic growth model.
temperature and the actual solid/liquid interface temperature. The
bulk temperature at the grain is known from the macromodel. The difference between the eutectic
temperature and this temperature gives bulk undercooling. The interfacial undercooling is obtained from
the bulk undercooling from a heat balance equation This is possible once the final grain size is known
from the nucleation law. The growth velocity of eutectic grains is given by the following equation, where
growth is assumed to take place by screw dislocation:
dRe

T2 C.16.10
dt
where is the growth constant. Both the stable and metastable eutectics are assumed to grow according
to the above equation. During growth, the partition of solute element between the solid and the liquid
phase is accounted for. The stable eutectic temperature is computed at each time by considering the
actual solute concentration in the liquid, as shown below:
T e
T e m( C e C e )
1 1
C.16.11
where Te and Ce are the equilibrium eutectic temperature and composition respectively. Te1 and Ce1 are
the eutectic temperatures and composition respectively at a given time step.
The rate of change of the fraction of solid is calculated with the Johnson-Mehl approximation, assuming
that the solid/liquid interface is weighted by the factor ( 1 -- f s ) to take into account the impingement of
grains toward the later part of solidification:
0 fs dR

(1 fs ) 4 % Re2 N e C.16.12
0t dt
where Re is the radius of eutectic grain and N is the substrate density. When the instantaneous
nucleation model is used, N becomes a function of cooling rate. For continuous nucleation, N becomes
a function of temperature.
Ductile Iron Eutectic Model
The eutectic growth process in ductile iron is a divorced

growth of austenite and graphite, which do not grow
concomitantly. At the beginning of the liquid/solid Liquid
transformation, graphite nodules nucleate in the liquid

Austenite
and grow in the liquid to a small extent, about 10 m. Graphite
The formation of graphite nodules and their limited
growth in liquid depletes the melt locally of carbon in the
vicinity of the nodules. This facilitates the nucleation of
austenite around the nodules, forming a shell. Further
growth of these nodules is possible by diffusion of carbon Cl
from the melt through the austenite shell. Ca
Cc
Mathematical simulation of this growth begins with an
instantaneous nucleation model that determines the final R CR aR l
Radius Temperature
grain size from the local cooling rate at the onset of
solidification. Second, once the austenite shell is formed Figure C-4 Schematic representation of an eutectic
around each nodule, the diffusion equation for carbon ductile iron grain and associated concentration profiles
and phase diagram. equiaxed eutectic growth model.
through the austenitic shell is solved in 1--D spherical
coordinates. The boundary conditions are known from
the phase diagram because thermodynamic equilibrium is maintained locally. Conservation of mass and
solute is maintained in each grain. Because of the density variation resulting from the growth of
austenite and graphite, the expansion/contraction of the grain is taken into account by allowing the final
grain size to vary. Toward the end of solidification, the grains impinge on each other. This is taken into
consideration by using the Johnson-Mehl approximation.

Figure C-4 shows a schematic representation of an eutectic ductile iron grain. This is the situation after
the graphite nodules grow in liquid to a limited extent following nucleation. Using a spherical coordinate
system, a mass balance is written as:
'c. 4 % Rc3 'a. 4 % (R a R c )

3 3
'l . 4 % ( Rl3 Ra3 )
mav C.16.13
3 3 3
where
'c, 'a, 'l are the densities of graphite, austenite, and liquid respectively
Rc, Ra, Rl are radii of graphite, austenite, and final grain respectively
mav is average mass of the grain
Assuming complete mixing of solute in liquid, the overall solute balance is written as:
Ra
'c.1. 4 % Rc3 'a.c(r, t) 4 % r 2 dr 'l cl . 4 % (Rl3 Ra3 )

cav C.16.14
3 Rc 3
Differentiation of the above two equations and use of Ficks' law in spherical coordinates leads to two
equations for graphite and austenite growth rates following some manipulation. This diffusion equation is
solved for the austenite shell with the following two boundary conditions:
1. at r = Rc, c(r,t) = cc
2. at r = Ra, c(r,t) = ca
where cc, ca are obtained from the phase diagram for temperature T as shown in Figure C-4. The liquid
concentration at this temperature is given as cl at temperature = T. cc, ca, cl are obtained from phase
diagram as shown in Figure C-4.
During solidification, the densities of the different phases are computed according to the following
equations:
l 1
'l
0.1201 12.67.10 6 T 9.0.10 4 w c 2.16.10 3 wSi
l
C.16.15
1
'a
0.1193 9.7.10 6 T 4.0.10 3 w c 2.2.10 4 w c
a a2
1.3.10 3 wSia C.16.16
'c
0.4419 10.5.10 6 T
1
C.16.17
where densities are given in cgs units and temperature in (K,
w c
wt % of carbon in liquid
l
w c
wt % of carbon in austenite
a
w Si
wt % of silicon in liquid
l
w Si
wt % of silicon in austenite
a
The average density of a ductile iron grain is given by:
'av
'l ( 1 fs ) 's fs C.16.18
where
4
% Rc3 'c 4
% (Ra3 Rc3 ) 'a
's
3 3
C.16.19
4
% Ra3
3
The densities are updated at each time based on the temperature. The rate of change of fraction of solid
is obtained with the following equation, which incorporates the Johnson-Mehl approximation for grain
impingement:
0 fs 0 Ra

( 1 fs ) 4 % Ra2 N C.16.20
0t 0t
The source term in the energy equation is computed using the above equation.

Gray/White Iron Eutectic Model
This model is a special case of coupled eutectic growth model and is applicable to cast iron only. In cast
iron, one may obtain both gray and white iron depending on the melt composition and cooling conditions.
Given a controlled melt composition, the most important factor that will determine whether a given region
will solidify as white or gray is the cooling rate. It has been observed that for a specific melt composition
and solidification condition, there exists a parameter called a critical cooling rate. If a region of a casting
solidifies with a cooling rate higher than the critical cooling rate, then it will be white. The reverse is the
case for gray iron. The white structure is brittle and in most gray iron castings, it is considered to be
deleterious.
This model differs from the Coupled Eutectic Growth Models previously described in that the nucleation
is described by a predetermined continuous distribution function. The nucleation rate equations for both
gray and white iron are obtained from the following equation:
N
A ( T )n C.16.21
where N is the final eutectic cell density. By experiment, it was found that A = 7.12 nuclei/cm3/K2 and n
= 2.
Differentiation of the above equation with respect to time leads to the following expression for the
nucleation rate:
dN

n A ( T )n 1 dT C.16.22
dt dt
The expression for growth rates was put forward by Oldfield, Magnin, and Kurz. The growth rate
equation follows an expression similar to Oldfield's nucleation rate equation. Using a spherical grain
approximation, the growth rate expression is given by:
dRe

B ( T )m C.16.23
dt
For gray iron, as reported by Magnin and Kurz, B is taken to be 38.7e-7 cm/s/K2 and m as 2. The
interfacial undercooling is T. For white iron, the value of B is taken from the work by Hillert to be
30.0e-6 cm/s/K2. It is apparent that white iron grows at a much faster rate than gray iron, which is also
an experimental fact. Appropriate expressions for nucleation and growth rates are used in the following
statistical approach.
Statistical Nucleation Model:
The distribution of nuclei are assumed to be described by a polynomial. The treatment in this section
follows recent work by Dantzig and coworkers. The nature of the polynomial is shown in Figure C-5 and
expressed by the following equation:
(r)
A1 A2 r A3 r 2 C.16.24
where (r) describes the cell density as a function of cell radius, r and A1, A2, A3 are constants to be
determined from the properties of the distribution.
Figure C-5 shows the distribution.
The three unknown parameters in the above equation are

obtained with the following three properties (Figure C-5 ):
1. At the maximum radius, R, the cell density is
zero.
2. The first derivative of the distribution evaluated at
the maximum radius is zero.
3. The area under the shaded area in Figure C-5,
which is the total number of cells in the
distribution, is N.
Figure C-5 Eutectic cell distribution assumed for

gray/white iron.
The following three equations describe these properties mathematically:
(R)
0 C.16.25
dn
r
R
0 C.16.26
dr
R
( r ) dr
N C.16.27
R0

Since the nuclei are assumed to be spherical, the fraction of solid can be locally expressed as:
R
fs
4 % r 3.(r).dr C.16.28
3
R0
After manipulation with the properties, an expression for the fraction of solid is obtained. Differentiation
of this expression leads to another expression that involves the nucleation rate and growth rate of nuclei.
The nucleation rates and growth rates for gray and white iron eutectic cells are obtained using equations
expressed earlier. To take into account impingement, the growth rate expressions are modified by the
use of Johnson-Mehl expression. Finally, the source term in the energy equation is obtained from the
time rate of change of fraction of solid.
Ductile Iron Eutectoid Model
This model may be used during the eutectoid

transformation while describing the complete phase
transformation of ductile iron from pouring temperature to
room temperature. Also it may be used when the iron is
heated from room temperature to the austenitizing
temperature and then annealed or normalized as part of a
heat treatment procedure.
The eutectoid reaction leads to the decomposition of

austenite into ferrite and graphite for the case of the
stable eutectoid and to pearlite for the metastable
eutectoid transformation. Usually, the metastable
eutectoid temperature is lower than the stable eutectoid
temperature. Slower cooling rates result in more stable
eutectoid structure.
Following solidification, the solubility of carbon in

Figure C-6 Schematic Representation of Eutectoid portion
austenite decreases with the drop in temperature until the of Fe-C-Si phase diagram.
stable eutectoid temperature, AT is reached (Figure C-6).
The rejected carbon migrates toward graphite nodules, which are the carbon sink. This results in carbon
depleted regions in austenite around the graphite nodules. This provides favorable sites for ferrites to
nucleate, which grow as a shell around graphite nodules. If the complete transformation of austenite is
not achieved when the metastable temperature, A1 in Figure C-6 is reached, pearlite forms and grows in
competition with ferrite.
Growth of Ferrite:
Even though ferrite can form either from the breakdown of pearlite or from the direct decomposition of
austenite, it is assumed here that ferrite results only from the latter source.
The following assumptions are made for modeling the growth of ferrite:
1. The austenite to ferrite transformation occurs at steady state and is controlled by carbon
diffusion.
2. The ferrite grains grow as spherical shells within austenite grains and the number of ferrite grains
is equal to the number of graphite nodules.
3. Thermodynamic equilibrium exists at graphite/ferrite and ferrite/austenite interfaces. These are
defined by equilibrium solvus lines extended below the equilibrium eutectoid temperatures.
4. Diffusion from the ferrite/austenite interface towards austenite is neglected as diffusion
coefficients and concentration gradients in austenite are small compared to those in ferrite.
Austenite (A)
Ferrite (F)
Graphite (G)
CG
CF/A
CA
CA/F Figure C-8 Eutectoid region of a binary Fe-C phase
diagram.
CG/F
RC RF Ra
Radius
Figure C-7 Schematic representation of the ferrite growth

model.

Solution of the diffusion equation of carbon in ferrite with the flux balance at the ferrite/austenite
interface leads to the following equation (see Figure C-7):
dRF ' F Rc C A /F C G/F

Dc C.16.29
dt 'F R F (R F R c ) C F /A C A /F
where
DcF = the carbon diffusion coefficient in ferrite
RF = the radius of the ferrite grain and graphite nodule
Rc = the radius of the graphite nodule
C , C , CA/F =
G/F F/A
carbon concentration in ferrite at the graphite/ferrite interface, carbon
concentration in ferrite at the ferrite/austenite interface, and carbon concentration
in austenite at the ferrite/austenite interface respectively (Figure C-7).
Since the rejected carbon migrates to the graphite nodule, concomitant growth of ferrite and graphite
results. The following equation derives from mass conservation:
'c 4 % (RC dRc )3 Rc CG
3
'F 4 % (RF dRF )3 RF C A/F
3
C.16.30
3 3
Therefore, knowing the radius of the ferrite grain, the radius of the graphite nodule can be obtained from
the above equation. Then the rate of change of fraction of ferrite grain is obtained by:
df F dRF

(1 fF fP ) 4 % N RF2 C.16.31
dt dt
where f F, f P are fractions of ferrite and pearlite, and N is the number of graphite nodules. The above
equation is used to obtain the source term due to ferrite growth associated with the stable eutectoid
transformation.
Nucleation and Growth of Pearlite:
The nucleation of pearlite usually occurs at austenite grain boundaries. It has been demonstrated that
pearlite colonies grow either as spheres or hemispheres following nucleation. By the movement of high
mobility ( i.e., low interface energy ) incoherent interfaces, these colonies can grow edgewise or sidewise
into the austenite. This means that pearlite grows in competition with ferrite until austenite is completely
transformed.
Transformation of austenite into pearlite is usually modeled with an Avrami equation because the study
of nucleation of pearlite is difficult, especially under continuous cooling conditions. Also, pearlite grains
impinge on each other at an early stage, especially at a relatively high cooling rate. Here, equations for
nucleation and growth of pearlite grains are taken from the work of Mehl and Dube:
dNpearl

5.07.106exp 370 C.16.32
dt Teud
dRpearl

0.0168 exp 94.8 C.16.33
dt Teud
where the pearlite nucleation density is given in nuclei/mm3/sec and the undercooling is given in (K. The
nucleation process stops once the minimum in the cooling curve is reached. The expression for the time
rate of change of fraction of pearlite transformed is given by an expression similar to that for ferrite.
Gray Iron Eutectoid Model
The gray iron eutectoid transformation model is based on the approach used for gray iron eutectic. Here
a statistical distribution is assumed. Details of this approach are given above in the explanation for the
gray iron eutectic model. Nucleation and growth of ferrite takes place once the temperature drops below
the stable eutectoid temperature. If the transformation of austenite is not complete when the metastable
eutectoid temperature is reached, then nucleation and growth of pearlite takes place.
In this statistical approach, nucleation and growth takes place once the temperature drops below the
transformation temperature. During nucleation, the radii of nuclei are introduced at R0 (Figure C-5).
Since the existing nuclei grow, both the cell density and maximum radii, R, increase, while the minimum
radius, R0, stays the same. When nucleation ends at the minimum point of the cooling curve, the
existing nuclei keep on growing until the transformed fraction becomes 1. The number of nuclei does not
change from this point on.
An instantaneous nucleation mechanism was used for ferrite. The growth of ferrite grains is controlled by
a diffusion mechanism as explained for the growth of the ductile iron eutectoid. The expression for
growth rate is given below:
C2 C3
F
dRferr Dc

dt C4 C3 1 C.16.34
2
RF 1
RF 0
RF
The above expression is derived by using a solute flux balance at the ferrite/austenite interface along

with the diffusion equation,

where
RF0 = the radius of ferrite nucleus
C2 = the carbon content in the middle of ferrite grain
C3 = the carbon content at the ferrite/austenite interface
C4 = the carbon content in austenite
The nucleation and growth rate expressions for pearlite are the same as those for the ductile iron
eutectoid model. These equations have been suggested by Mehl and Dube.
All of the above equations are solved as a linear system by the use of Gauss elimination. The rate of
change of fraction of pearlite and ferrite transformed are used to calculate the source term in the
macroscopic energy equation at each time step.
Peritectic Transformation Model
In a peritectic transformation, liquid reacts with an existing solid phase to form a new solid phase. In
conventional models, the new solid is assumed to form at the interface between the parent liquid and
solid phases. Once the new solid phase is formed, further reaction between the parent phases is limited
by the layer of solid formed. Hence the rate of reaction is controlled by the diffusion of solute through
the shell of the transformed product.
The following discussion is for the Fe-C system. However, it is valid for all other systems undergoing a
peritectic transformation, with a few relevant assumptions. It has been suggested by some researchers
that the peritectic transformation may be achieved through a liquid layer in between the parent and the
product solid phases. This mechanism has been adopted in the present model. For example, in the
case of steel, the austenite phase forms initially at the root of the dendrite arms of the delta phase and
grows along the delta/liquid interface. The speed of this growth is the same as that with which liquid
moves toward the delta phase. The diffusion problem can be simplified as the liquid layer is very thin
and the diffusion of carbon in the liquid is very rapid so that the carbon concentration gradient in the
liquid is negligible. Here the solute diffusion boundary layer is much greater than the system size i.e.,
the following condition holds:
2 Dl
c
L C.16.35
V
where
c = the thickness of the boundary layer
Dl = the solute diffusivity in liquid
V = the speed of growth
L = the system size
It is assumed that the above condition is maintained for any system undergoing peritectic transformation.
The model is based on a Brody-Flemings formulation, with recent modifications suggested by Zou and
Tseng. For the peritectic transformation given by the reaction,
L
C.16.36
the following mass balance equation may be written:
s, s,
[ ( f L.CL Cs, ) ( f L.Cl f Cs, ) ] df s
(1 f s ) dCl dCs, dCs, C.16.37
2L 2L
where
f L and f
fractions of liquid and delta phases reacting
Cl
the liquid concentration

Cs, and Cs,
solute concentrations at the delta/liquid and austenite/liquid interfaces respectively
L
the system size
dCl
the change solute concentration in liquid
s, and s,
the solute boundary layer thicknesses in gamma and delta phases
After some mathematical manipulation, an expression is obtained that relates the solute concentration in
liquid with the fraction of solid transformed, involving some parameters such as dimensionless
coefficients for back diffusion for both delta and austenite phases i.e., and . According to the
Brody-Flemings model, the case of = 0.5 does not correspond to the physical characteristics of
equilibrium solidification. In that case, should approach infinity. Therefore, a modified back diffusion
parameter, 1 has been proposed by Clyne and Kurz. The basis of this calculation is that, in the original
Brody-Flemings treatment for high values, solute was not conserved in the system. According to
Clyne and Kurz, the modified back diffusion parameter is defined as:
1
1 exp
1
1 exp 1 C.16.38
2 2
Differentiation of the equation involving fraction transformed and solute concentration in liquid leads to
the expression for rate of change of fraction of solid assuming thermodynamic equilibrium at the
solid/liquid interface, which is used to calculate the source term in the energy equation.

Solid Transformation Models
This model is only applicable to the Fe-C system and is used for tracking the fraction transformed for the
cases of delta to gamma, gamma to ferrite, and gamma to cementite.
A hypoeutectoid steel may form some delta phase in the beginning while the remaining liquid and some
delta phase undergo a peritectic transformation to form some gamma phase. The remaining delta phase
gets transformed to gamma phase. This transformation is addressed by the present model. Delta to
gamma transformation will be active in the appropriate temperature range when the wt% carbon
equivalent value is less than 0.17%.
The delta to gamma phase transformations can be described by the Johnson-Mehl equation, also known
as Avrami equation:
f v
1 exp [ k(T) t n ] C.16.39
where
f v = the fraction transformed
f v = the fraction transformed
k(T) = the rate constant
The rate constant is a function of nucleation and growth rates. It depends on the transformation
temperature and is related to the shape and position of the C curve in a TTT (
time-temperature-transformation ) diagram. In most cases, this curve has a parabolic shape and can be
approximated as:
k (T )
exp ( aT 2 bT c ) C.16.40
where T represents temperature in K. The parameters a, b, c, n have been determined for each of these
transformations. Appropriate values are chosen for this transformation from the literature.
Differentiation of the equation for fraction transformed with respect to time leads to the expression for the
time rate of change of fraction of delta transformed to gamma.
Again, prior to reaching the eutectoid temperature, some of the austenite phase may transform into alpha
phase as part of a pro-eutectoid transformation. If you started with a hypereutectoid composition, the
pro-eutectoid transformation will be from austenite ( gamma ) to cementite. Both of these pro-eutectoid
transformations are addressed by the current model. The wt% carbon equivalent determines whether the
gamma to ferrite or gamma to cementite transformation will be used. Both of these models require that
the equiaxed dendrite model be chosen for the initial liquid/solid phase transformation.
The radius of the transformed ferrite or cementite grain is obtained with the following equation:
Tp
1
R
V (T ) dT C.16.41
T
T
where
T = cooling rate
V(T) = the growth velocity of the ferrite or cementite grain
Assuming steady state thickening, the growth velocity at a given temperature is:
D C C0 )
2
V
C.16.42
2x (C0 C)
where
D = the diffusivity of carbon in austenite
C = the concentration in austenite at ferrite/austenite interface
C = the concentration in ferrite at ferrite/austenite interface
Co = the original solute concentration in the alloy
x = the radius of ferrite
Fraction of austenite transformed into ferrite is given as:
2
f
R C.16.43
d
where
f = the fraction transformed
d = the austenite grain size
Similar equations have been used for the gamma to cementite transformation, where the growth velocity
equation and associated data are obtained from published literature.

Scheil Model
The Scheil model makes the assumptions of complete mixing of solute in liquid and no solute diffusion in
the solid phase. The following equation describes the differential form of the Scheil equation:

(cl cs ) df s
(1 f s ) dcl C.16.44
where

cl
the liquid composition at the solid/liquid interface

cs
the solid composition at the solid/liquid interface
dcl
the change in concentration in liquid
f s
the fraction of solid
Consider a portion of a binary phase diagram as shown in Figure C-9.
Tm
Tl
T
Ts
Cs Co Cl
Solute Concentration
Figure C-9 A portion of a binary phase diagram.
In Figure C-9, Tl and Ts are the liquidus and solidus temperatures respectively. cl and cs are solute
concentrations in the liquid and solid phases at some temperature, T. co is the initial solute concentration
in the alloy and Tm is the melting point of the pure solvent.
The change of fraction of solid obtained with the above equation is used for the calculation of the source
term in the macroscopic energy equation.
Output of Micromodels
Equiaxed Dendrite Model
This primary dendrite solidification yields the following spatially varying output:
1. DENDRITE RADIUS
2. DENDRITE TIP COMPOSITION
3. PRIMARY FRACTION OF SOLID
4. PRIMARY INT. SOLID FRACTION
5. SECONDARY DENDRITE ARM SPACING
The DENDRITE RADIUS provides the current position of the dendrite tip and volume fraction of the
dendritic grain as it varies with time. At the end of the primary solidification, this parameter will equal the
final grain radius as calculated from the instantaneous nucleation law with the prevailing cooling rate
value. This is true provided a terminal reaction such as an eutectic reaction does not take place
beforehand. Subtraction of the value of the PRIMARY FRACTION OF SOLID at the beginning of the
eutectic reaction provides the total amount of the eutectic at a given location. The PRIMARY INT.
SOLID FRACTION parameter increases from a small value to unity as the primary solidification
proceeds. It is the ratio of the current volume of the grain as known from the DENDRITE RADIUS and
the final volume of the grain as known from the nucleation law. At the onset of the eutectic reaction,
subtraction of the value of the PRIMARY INT. SOLID FRACTION from unity provides the amount of the
fraction of the eutectic between the grains. Subtraction of this amount of eutectic between grains from
the total amount of the eutectic provides the amount of eutectic between dendrite arms. In most cases, it
is important to know how much eutectic will form between grains and between dendrite arms.
With the progress of solidification, the DENDRITE TIP COMPOSITION parameter will continuously
change from the initial to the eutectic composition. A map of this parameter over the entire casting at a
given instant gives an idea about microsegregation, since the concentration of the solid phase forming is
proportional to the tip concentration. The information about microsegregation is important for describing
non-equilibrium behavior in castings. This is the cause of interdendritic precipitation of eutectic, even if
the initial alloy composition is not on eutectic tie line.
The SECONDARY DENDRITE ARM SPACING (SDAS), which is the spacing between the secondary
arms of a dendrite, depends upon the local solidification time. As the SDAS increases, the mechanical
properties deteriorate. SDAS also determines the spacing of precipitates and/or porosity. The
Secondary Dendrite Arm Spacing is output when either the eutectic transformation model and/or the
peritectic transformation model are used.
Coupled Eutectic Growth Model with Instantaneous Nucleation
1. LARGE EUT. GRAIN RADIUS

2. EUTECTIC FRACTION OF SOLID
3. INTER-LAMELLAR SPACING
4. METASTABLE EUT. GRAIN RAD.
5. MET. EUTECTIC FR. OF SOLID
The LARGE EUT. GRAIN RADIUS and METASTABLE EUT. GRAIN RAD. parameters provide the

instantaneous value of the stable and metastable eutectic grain radii, which can be used to control the
mechanical properties of the cast part. The EUTECTIC FRACTION OF SOLID and MET. EUTECTIC
FR. OF SOLID parameters give the relative amount of stable and metastable eutectic structure. For
example, in cast iron the metastable eutectic (white) may be undesirable. The INTER-LAMELLAR
SPACING parameter determines the fineness of the eutectic. Smaller values of this parameter provide
better mechanical properties. The Jackson-Hunt equation for the eutectic interlamellar spacing is given
with the following equation:
2 V
K C.16.45
Where, V is the velocity at the eutectic front. The velocity of the eutectic front can be expressed in the
following form:
V
( T )2 C.16.46
Here, T is the interfacial undercooling at the eutectic front. Combining the above two equations, the
following equation is written:
Vt t
Vt t 2t t
2
C.16.47
The instantaneous value of the inter-lamellar spacing is obtained with the above equation. At the end of
solidification, an average value of the inter-lamellar spacing is obtained.
Coupled Eutectic Growth Model with Continuous Nucleation
The following parameters are similar to those for the Coupled Eutectic Growth Model with Instantaneous
Nucleation. The only additional quantity is the EUTECTIC GRAIN RADIUS, which gives the stable
eutectic grain density as a function of time over the entire casting. In many cases, a large number of this
parameter will be desirable from the standpoint of mechanical properties.

3. EUTECTIC GRAIN RADIUS
4. INTER LAMELLAR SPACING
Ductile Iron Eutectic Model

The following parameters are displayed when this particular micromodel is selected.
1. AUSTENITE RADIUS
2. GRAPHITE RADIUS
The EUTECTIC GRAIN RADIUS parameter gives the final radius of eutectic grains over the entire
casting. This is governed by the function used to describe the dependence of the nodule count on the
cooling rate. In ductile iron, each eutectic grain consists of a graphite nodule enveloped in an austenite
shell. The AUSTENITE RADIUS and GRAPHITE RADIUS provide the instantaneous values of the
solidified grain size and nodule size respectively. At the end of solidification, they provide a correct
description of the final grain size and nodule size. The AUSTENITE RADIUS should in principle coincide
with the final grain size as given by the EUTECTIC GRAIN RADIUS parameter. However, because of
the grain impingement, AUSTENITE RADIUS may exceed the EUTECTIC GRAIN RADIUS. A map of
the EUTECTIC FRACTION OF SOLID parameter can be used to determine areas of shrinkage formation
in castings. AUSTENITE RADIUS AND GRAPHITE RADIUS can be related to the mechanical
properties of castings. Density is calculated from the local fraction of graphite, austenite, and liquid, thus
capturing the peculiar contraction and expansion behavior of ductile iron.
Gray/White Iron Eutectic Model

This model uses a statistical distribution for nucleation.
2. SMALL EUT. GRAIN RADIUS
3. FRACTION OF SOLID
5. INTER LAMELLAR SPACING
7. SMALL MET. EUT. GR. RADIUS
9. MET. EUTECTIC GR. DENSITY
The LARGE EUT. GRAIN RADIUS and SMALL EUT. GRAIN RADIUS refer to the maximum and
minimum values of the stable (gray) eutectic grain radius as a function of time during eutectic growth.
Similarly, METASTABLE EUT. GRAIN RAD. and SMALL MET. EUT. GR. RADIUS parameters are
relevant for the metastable (white) eutectic. Mechanical properties of the cast part are a function of the
stable and metastable eutectic grain sizes. FRACTION OF SOLID gives the amount of the gray eutectic,
whereas MET. EUTECTIC FR. OF SOLID gives the amount of the white eutectic. In most cases, the
gray structure is more desirable as it gives improved tensile strength and ductility. The EUTECTIC
GRAIN RADIUS parameter gives the gray eutectic grain density and the MET. EUTECTIC GRAIN
DENSITY gives white eutectic grain density. These two parameters are connected to mechanical
properties in a similar fashion to the grain radius parameters. The Eutectic Grain Density of Gray and
White Iron are used to describe the number of grains per unit volume at a given location of a casting.
This can be correlated with the mechanical properties of the cast part. The INTER LAMELLAR
SPACING parameter calculates the spacing of the gray eutectic which is explained under Coupled
Eutectic Growth Model with Instantaneous Nucleation.
Ductile Iron Eutectoid Model

As explained earlier, the stable eutectoid growth refers to the decomposition of austenite into ferrite and
graphite and the metastable eutectoid growth refers to the decomposition of austenite into pearlite, which
is a coupled growth of ferrite and cementite.
1. LARGE FERRITE GR. RADIUS

2. FRACTION OF FERRITE
3. FRACTION OF PEARLITE
4. LARGE PEARLITE GR. RADIUS
5. LOCAL PEARLITE GRAIN DENSITY
The properties of the iron depend strongly on the relative amounts of ferrite and pearlite in the matrix.
As the pearlite content increases, tensile and yield strengths also increase, but at the cost of ductility.
Ferrite content controls fracture toughness and dynamic properties of iron. The amount of ferrite
increases as the nodule count of the iron increases. The FRACTION OF FERRITE and FRACTION OF
PEARLITE give the relative amount of stable and metastable eutectoid structures. The pearlite/ferrite
ratio can be related to tensile strength through its effect on matrix microhardness. The LARGE
FERRITE GR. RADIUS and LARGE PEARLITE GR. RADIUS provide the stable and metastable
eutectoid grain radii as a function of time. LARGE PEARLITE GR. RADIUS can provide a qualitative
estimate of interlamellar spacing, which can be related to mechanical properties. Also, LOCAL
PEARLITE GRAIN DENSITY can be used to estimate the mechanical properties. Usually, a finer
pearlite grain size is associated with a finer interlamellar spacing with better mechanical properties.
Gray Iron Eutectoid Model
This model uses a statistical distribution of nuclei as explained for Eutectic Gray/White Iron model.
1. LARGE FERRITE GR. RADIUS

2. SMALL FERRITE GR. RADIUS
3. LARGE PEARLITE GR. RADIUS
4. SMALL PEARLITE GR. RADIUS
5. FRACTION OF FERRITE
6. FRACTION OF PEARLITE
7. LOCAL PEARLITE GRAIN DENSITY
The above parameters reflect the same kind of behavior as they do in the case of the Ductile Iron
Eutectoid Model. The only difference is that stable and metastable eutectoid grain sizes are provided as
a range extending from a minimum value to a maximum value.
Peritectic Transformation Model
1. PERITECTIC FR. OF SOLID

2. LIQUID CONCENTRATION
Usually, peritectic growth is limited by the formation of the solid transformed product at the reacting
liquid/solid phase boundary. The PERITECTIC FR. OF SOLID parameter gives the volume fraction of
solid resulting from this reaction. It is important to know the amount of the phase formed through this
reaction, as it usually forms as a surface layer on the primary dendritic solid phase. Segregation of
solute is a problem during this reaction, as diffusion is limited in the transformed phase. LIQUID
CONCENTRATION provides a measure of this effect as a function of time. Segregation is a problem
unless the cast part undergoes significant plastic deformation and heat treatment later on.
Solid Transformation Models
1. FRACTION TRANSFORMED
2. FRAC. OF PROEUTECTOID PHASE
The FRACTION TRANSFORMED parameter refers to the delta to gamma phase transformation. The
FRAC. OF PROEUTECTOID PHASE refers to the fraction of proeutectoid ferrite or cementite formed
from the austenite phase as a function of time. The carbon equivalent value controls which type of the
proeutectoid phase (ferrite or cementite) will form.
Scheil Model
The Scheil Model is usually used to model the primary dendrite growth.
1. PRIMARY FRACTION OF SOLID

2. LIQUID CONCENTRATION
The PRIMARY FRACTION OF SOLID parameter provides the time-dependent evolution of the primary
solid fraction. The LIQUID CONCENTRATION parameter gives the progressive concentration in the
liquid at the solid/liquid interface of the solidifying grain. This is also the concentration in the entire liquid
phase of the grain since the Scheil model assumes complete solute mixing in liquid. Since the effect of
the undercooling at the tip is not taken into consideration, this model will not predict any variation in
primary solid fraction as a function of cooling rate as one observes in an equiaxed dendrite model.

Interlamellar spacing
The interlamellar spacing that is addressed here is based

on the Jackson-Hunt model of eutectic growth. It is
assumed that the interlamellar spacing follows the
extremum criterion condition, which means that such
interlamellar spacing will be chosen by the system so as
to minimize the undercooling at the eutectic front. In
other words, it is assumed that the growth valocity is
maximized for the extremum condition. It may be
mentioned here that the Jackson-Hunt theory is valid
under steady state growth conditions. In castings, the
growth process is unsteady except during the eutectic
plateau of the cooling curve. The growth process during
eutectic arrest is close to steady state growth. Therefore, Figure C-10
while viewing the contours of this parameter over the
casting, you should be in the steady state growth range. Toward the end of eutectic solidification, the
growth rate is rapidly increased. Therefore, the interlamellar spacing calculated at that time may not be
representative of the actual spacing.
The expression for the Jackson-Hunt theory of eutectic growth is given by the following equation:
Kr
2ex V
C.16.48
Kc
where
ex =the interlamellar spacing based on the extremum condition
V = the growth velocity of the eutectic front
The expressions for the parameters Kr and Kc are obtained from the following, assuming that the eutectic
structure is composed of and phases:
m C1 P1
Kc
C.16.49
f (1 f ) D
and

sin ()
sin ()
Kr
2 m C.16.50
fm (1 f ) m
where
m m
m
C.16.51
m m
sin 2 (n % f)
1
P1
C.16.52
M
n 3
%
3
where
m and m = absolute liquidus slopes in and side of the phase diagram

and
= Gibbs-Thompson coefficients associated with and phases respectively
f= the volume fraction of the phase
C1 = the difference in composition between the ends of the eutectic tie line
D= the diffusion coefficient in liquid
and = the angles are the angles subtended by the tangents of and interfaces with the
line OY at the intersection of and interfaces (see Figure C-10).
The equation of interlamellar spacing is rewritten as:
(Kr / Kc)
ex
C.16.53
V

The Jackson-Hunt Parameter here refers to the value of Kr/Kc. Typical experimental values for this
parameter for different systems are listed below:
Eutectic Systems Kr/Kc(mm3s-1)
Ag-Pb 1.2. 10-7
Ag3Sn-Sn 2.8.10-7
Al-Al2Cu 1.2. 10-7--1.4. 10-7 (function of C0)
Al-Si 5.8. 10-7--3.1. 10-6 (function of G)
Al-Zn 6.4. 10-8
Bi-Zn 6.9. 10-8
Cd-Pb 2.1. 10-8
Cd-Sn 7.2. 10-8
Cd-Zn 2.8. 10-8
Fe-C 5.6. 10-6
Pb-Sn 2.8. 10-8--3.3. 10-8
Sn-Zn 6.9. 10-8
Section 17: Cooling Curve Analysis
If the internal thermal gradients in a sample are negligible (i.e., if the temperature in the sample is
uniform), then the following heat balance equation may be written for the solidifying sample-mold
system:
Heat transferred to mold = Heat generated by phase transformation --- Heat lost by metal
Mathematically, this is expressed with the following equation:
dQ L
' V Cp dT
hA( T To ) (C.17.1)
dt dt
where
QL = latent heat of phase transformation
' = density of metal
Cp = Specific heat of metal
T = metal temperature
t = time
h = heat transfer coefficient
A = surface area
V = volume of sample
To = ambient temperature
The above equation is rearranged as:
dQ L
( ' V Cp )
dT

hA( T T0 ) (C.17.2)
dt cc dt
This equation is valid for the cooling curve. If there is no phase transformation during cooling of metal,
dQ L
then is zero. Therefore, the following equation is written:
dT
( ' V Cp )
dT

hA(T T0 ) (C.17.3)
dt zc
Here, the subscript zc represents the zero curve. Taking the difference between these two equations, the
following equation is written:
dQ L

' V Cp dT
dT (C.17.4)
dt dt cc dt zc
Integration of this equation yields:
tf
QL
' VCp dT
dT dt (C.17.5)
dt cc dt zc
o
Here, tf is the solidification time. Therefore, the latent heat for phase transformation is obtained as L =
QL/'V.

PREFIXD.DAT FILE FORMAT
APPENDIX D
prefixd.dat FILE FORMAT
The formatted file containing the description of the problem is the prefixd.dat file. This file is normally created by PreCAST and
processed by DataCAST to check for errors in the model and then create the binary simulation file.
It is possible to create the prefixd.dat file manually if the problem is small. However, it is much more likely that you would want to make
minor changes in the problem setup, such as changing one heat transfer coefficient, by editing the prefixd.dat file.
This appendix provides a description of the records and record formats in this file. Each record of the prefixd.dat file is identified by the
two labels LA and LB. These two numbers must be in 2I2 format. If there are any units in the record, they must be in the format given.
Everything else can be in free format.
( 1, 0 ) Data Set - Title statements
Input: LA, LB, TITLE

Format: 2I2, A80
Content: LA =1
LB =0
TITLE = Arbitrary line of information for run documentation
Note: Up to three records of this type may be included.
( 1, 1 ) Data Set - Number of nodes and elements
Input: LA, LB, NTNOD, NTEL

Format: 2I2, 1X, 2I10
Content: LA =1
LB =1
NTNOD = Total number of nodes
NTEL = Total number of elements
( 2, 0 ) Data Set - Control parameters
Input: LA, LB, THERMAL, FREE_SURFACE, TWO_D

Content: LA =2
LB =0
THERMAL = 0 for no thermal solution ( flow only )
= 1 for thermal solution
FREE_SURFACE = 0 for no free surface flow
= 1 for free surface flow ( filling transients )
TWO_D = 0 for 3D geometry
= 1 for 2D Cartesion geometry
= 2 for 2D cylindrical geometry
APPENDICES, PAGE D - 1
(3, 0 ) Data Set - Solid element information
Input: LA, LB, IEL, ITYPE, MINDEX, NODE1, ... NODE10

Format: 2I2, 1X, 3I5, 10I7
Content: LA =3
LB =0
IEL = Element number
ITYPE = 1 for 8-node brick element
= 2 for 4-node tetrahedral element
= 3 for 6-node wedge element
= 6 for 4-node quadrilateral element
= 7 for 3-node triangular element
= 9 for 2-node bar element
= 10 for 10-node tetrahedral element
N = Material ID number, points to Data Set ( 3, 1 )
NODE1, = Connectivity data
...NODE*
( 3, 1 ) Data Set - Solid element additional information
Input: LA, LB, U1, N, MTYPE, FLUID, FILLED, VINDEX, THETA, TIC, UPDATE, MOLD, STRESS
Format: 2I2, 1X, I1, 4X, 5I3, 2E15.0, 3I5
Content: LA =3
LB =1
U1 = Units for initial condition temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
N = Material ID number
MTYPE = Material number in Data Set ( 5, 0 )
FLUID = 0 this material does not flow
= 1 normal flow material
= 2 filter material
= 3 foam material
FILLED = 0 if elements with this index are initially empty
= 1 if elements with this index are initially filled
VINDEX = Pointer to Data Set ( 6, 5 ) for moving solid elements
THETA = Implicit-explicit time stepping parameter
TIC = Temperature initial condition for elements with this index
UPDATE = Frequency at which to reintegrate the element matrices for this ID
MOLD = 0 if this ID does not represent a mold
= 1 if this ID represents a mold
This is only used when running multiple cycles with the parameters TCYCLE and
NCYCLE..
STRESS = 0 no stress calculation for this material
= 1 linear elastic material
= 2 plastic, linear hardening material
= 3 plastic, power law hardening material
= 4 viscoplastic 1, linear hardening material
= 5 viscoplastic 1, power law hardening material
= 6 viscoplastic 2, linear hardening material
= 7 viscoplastic 2, power law hardening material
Note: The FLUID parameter should be 0 for 1D elements
PAGE D - 2 PROCAST USERS MANUAL

( 3, 2 ) Data Set - 1D Conduction element information
Input: LA, LB, U1, IEL, INDEX, NODE1, NODE2, AREA

Format: 2I2, 1X, I1, 4X, 2I5, 2I7, E15.0
Content: LA =3
LB =2
U1 = Units for the cross-sectional area
= 1 for meters**2
= 2 for centimeters**2
= 3 for millimeters**2
= 4 for feet**2
= 5 for inches**2
INDEX = Pointer to Data Set ( 3, 1 )
NODE2
AREA = Cross-sectional area
( 3, 3 ) Data Set - 1D Interface element information
Input: LA, LB, U1, IEL, INDEX, NODE1, NODE2, AREA

Format: 2I2, 1X, I1, 4X, 2I5, 2I7, E15.0
Content: LA =3
LB =3
U1 = Units for the cross-sectional area
= 1 for meters**2
= 4 for feet**2
= 5 for inches**2
NODE2
AREA = Cross-sectional area
( 4, 0 ) Data Set - Node coordinates
Input: LA, LB, U1, NODE, X, Y, Z

Format: 2I2, 1X, I1, 4X, I5, 3E15.0
Content: LA =4
LB =0
U1 = Units of the coordinates
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
NODE = Node number
X,Y,Z = Cartesian coordinates of NODE
( 4, 1 ) Data Set - Enclosure node coordinates
Input: LA, LB, U1, NODE, X, Y, Z

Format: 2I2, 1X, I1, 4X, I5, 3E15.0
Content: LA =4
LB =1
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
NODE = Enclosure node number
X,Y,Z = Cartesian coordinates of NODE
( 4, 2 ) Data Set - Radial symmetry information
Input: LA, LB, U1, NSS, NAXIS, X, Y, Z

Format: 2I2, 1X, I1, 4X, 2I5, 3E15.0
Content: LA =4
LB =2
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
NSS = Number of symmetric structures ( default =1)
NAXIS = 1 for first point defining the axis of symmetry
= 2 for second point defining the axis of symmetry
X,Y,Z = Cartesian coordinates of NAXIS
Note: Two records of this type are required if the radial symmetry option is being used.
( 4, 3 ) Data Set - Mirror symmetry information
Input: LA, LB, U1, NPLANE, X, Y, Z

Format: 2I2, 1X, I1, 4X, I5, 3E15.0
Content: LA =4
LB =3
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
NPLANE = 1 for first point defining plane of symmetry
= 2 for second point defining plane of symmetry
= 3 for third point defining plane of symmetry
X,Y,Z = Cartesian coordinates of NPLANE
Note: Three records of this type are required if the mirror symmetry option is being used

( 4, 4 ) Data Set - Gravitational acceleration vector
Input: LA, LB, U1, AX, AY, AZ

Format: 2I2, 1X, I1, 4X, I5, 3E15.0
Content: LA =4
LB =4
U1 = Units for acceleration
= 1 for m / sec**2
= 2 for cm / sec**2
= 3 for mm / sec**2
= 4 for ft / sec**2
= 5 for in / sec**2
AX = X component of gravity
AY = Y component of gravity
AZ = Z component of gravity
( 4, 5 ) Data Set - Gravitational vector rotation
Input: LA, LB, U1, TIME, X1, Y1, Z1, X2, Y2, Z2
Format: 2I2, 1X, I1, 4X, I5, 6E10.0
Content: LA =4
LB =5
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
TIME = Time function number
X1,Y1,Z1 = Coordinates for first point of rotation axis
X2,Y2,Z2 = Coordinates for second point of rotation axis
( 4, 6 ) Data Set - Rotation data for Periodic Boundary
Input: LA, LB, U1, N, NAXIS, THETA, X, Y, Z

Format: 2I2, 1X, I1, 4X,2I5, 4E15.0
Content: LA =4
LB =6
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
N = Periodic data set number
NAXIS = 1 for first point defining the axis of rotation
= 2 for second point defining the axis of rotation
THETA = Angle of rotation
Note: Two records of this type are required if the periodic boundary involves rotation
( 4, 7 ) Data Set - Translation data for Periodic Boundary
Input: LA, LB, U1, N, DX, DY, DZ

Format: 2I2, 1X, I1, 4X, I5, 3E15.0
Content: LA =4
LB =7
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
N = Periodic data set number
DX = Translation in X direction
DY = Translation in Y direction
DZ = Translation in Z direction
( 4, 8 ) Data Set - Centrifugal data
Input: LA, LB, U1, U2, NAXIS, TIME, OMEGA, X, Y, Z

Format: 2I2, 1X, 2I1, 3X, 2I5, 4E15.0
Content: LA =4
LB =8
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
U2 = Units for angular velocity
= 1 for radians / second
= 2 for radians / minute
NAXIS = 1 for first point defining the axis of rotation
= 2 for second point defining the axis of rotation
TIME = Time function number for angular velocity
OMEGA = Constant angular velocity
Note: Two records of this type are required if the centrifugal option is being used.
( 5, 0 ) Data Set - Material properties
Input: LA, LB, INDEX, NAME, IENTH

Format: 2I2, 1X, A30, I5
Content: LA =5
LB =0
INDEX = Corresponds to MTYPE in Data Set ( 3, 1 )
NAME = Material name
IENTH = Enthalpy curve index, corresponds to set ( 5, 5 )

( 5, 1 ) Data Set - Density Information
Input: LA, LB, U1, MAT, ITEMP, RHO

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB =1
U1 = Units for density
= 1 for kg / m**3
= 2 for g / cm**3
= 3 for g / mm**3
= 4 for lb / ft**3
= 5 for lb / in**3
MAT = Material number
ITEMP = Temperature function index for RHO
RHO = Baseline or constant density
( 5, 2 ) Data Set - Specific Heat / Enthalpy Information
Input: LA, LB, U1, MAT, ITEMP, CP

Format: 2I2, 1X, I1, 4X, 3I5, E15.0
Content: LA =5
LB =2
U1 = Units for specific heat
= 1 for kJ / kg / K
= 2 for cal / g / C
= 3 for Btu / lb / F
ITEMP = Temperature function index for CP
CP = Constant specific heat
( 5, 3 ) Data Set - Conductivity Information
Input: LA, LB, U1, MAT, ITEMP, COND, ANISO

Format: 2I2, 1X, I1, 4X, 2I5, E15.0, E15.0
Content: LA =5
LB =3
U1 = Units for thermal conductivity
= 1 for W / m / K
= 2 for cal / cm / C / sec
= 3 for cal / mm / C / sec
= 4 for Btu / ft / F / sec
= 5 for Btu / in / F / sec
= 6 for cal / cm / C / min
= 7 for Btu / ft / F / min
= 8 for Btu / in / F / min
ITEMP = Temperature function index for COND
COND = Baseline or constant conductivity
ANISO = anisotropic multiplier which is applied in the t parametric direction for 8 noded brick
elements and 6 noded wedge elements. In the case of a 4 noded quadralaterial
element, the anisotropic multiplier is applied in the s parametric direction.
Note: The ANISO parameter is optional.
( 5, 4 ) Data Set - Viscosity Information
Input: LA, LB, U1, MAT, ITEMP, VIS

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB =4
U1 = Units for viscosity
= 1 for Pascal - sec
= 2 for N - sec / m**2
= 3 for centpoise
= 4 for poise
= 5 for lb / sec / ft
= 6 for lb / min / ft
= 7 for lb / hr / ft
ITEMP = Temperature function index for VIS
VIS = Baseline or constant viscosity for newtonian flow
( 5, 5 ) Data Set - Enthalpy curves
Input: LA, LB, U1, U2, CURVE, POINT, TEMP, VALUE

Format: 2I2, 1X, 2I1, 3X, 2I5, 2E15.0
Content: LA =5
LB =5
U1 = Units for temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
U2 = Units for enthalpy
= 1 for kJ / kg
= 2 for cal / g
= 3 Btu / lb
CURVE = Corresponds to IENTH in Data Set ( 5, 0 )
POINT = Number of point on the curve
TEMP = Temperature of point
VALUE = Enthalpy value of point
( 5, 6 ) Data Set - Fraction Solid and Latent Heat
Input: LA, LB, U1, MAT, ITEMP, LHEAT

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB =6
U1 = Units for latent heat
= 1 for kJ / kg
= 2 for cal / g
= 3 Btu / lb
ITEMP = Temperature function index for fraction solid
LHEAT = Latent heat

( 5, 7 ) Data Set - Liquidus and Solidus Temperatures
Input: LA, LB, U1, U2, MAT, LIQUID, SOLID

Format: 2I2, 1X, I1, 4X, I5, 2E15.0
Content: LA =5
LB =7
U1,U2 = Units for temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
LIQUID = Liquidus temperature
SOLID = Solidus temperature
( 5, 8 ) Data Set - Mold Permeability
Input: LA, LB, U1, MAT, PERM

Format: 2I2, 1X, I1, 4X, I5, E15.0
Content: LA =5
LB =8
U1 = Units for permeability
= 1 for meters**2
= 4 for feet**2
= 5 for inches**2
MAT = Material number ( points to 5 0 card )
PERM = Permeability
( 5, 9 ) Data Set - Surface Tension Information
Input: LA, LB, U1, MAT, ITEMP, ST

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB =9
U1 = Units for surface tension
= 1 for N / m
= 2 for dyne / cm
= 3 for lb / ft
= 4 for lb / in
MAT = Material number ( points to 5 0 card )
ITEMP = Temperature function index for ST
ST = Baseline or constant surface tension
( 5, 10 ) Data Set - Transformation Temperature
Input: LA, LB, U1, INDEX, ICOOL, TT

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 10
U1 = Units for transformation temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
INDEX = Reference index for Data Sets ( 5, 16 ) to ( 5, 24 )
ICOOL = Cooling rate function index
TT = Constant transformation temperature
( 5, 11 ) Data Set - Partition Coefficient
Input: LA, LB, INDEX, ITEMP, PC

Format: 2I2, 1X, 5X, 2I5, E15.0
Content: LA =5
LB = 11
ITEMP = Temperature function index
PC = Baseline or constant partition coefficient
( 5, 12 ) Data Set - Solute Diffusivity
Input: LA, LB, U1, INDEX, ITEMP, DIFF

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 12
U1 = Units for diffusivity
= 1 for m**2 / sec
= 2 for cm**2 / sec
= 3 for mm**2 / sec
= 4 for ft**2 / sec
= 5 for in**2 / sec
= 6 for m**2 / min
= 7 for cm**2 / min
= 8 for mm**2 / min
= 9 for ft**2 / min
= 10 for in**2 / min
ITEMP = Temperature function index
DIFF = Baseline or constant solute diffusivity

( 5, 13 ) Data Set - Liquidus Slope
Input: LA, LB, U1, INDEX, ICONC, LS

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 13
U1 = Units for liquidus slope
= 1 for K / wt%
= 2 for C / wt%
= 3 for F / wt%
= 4 for R / wt%
ICONC = Concentration function index
LS = Baseline or constant liquidus slope
( 5, 14 ) Data Set - Substrate Density, Nodule Count
Input: LA, LB, U1, INDEX, IFUNC

Format: 2I2, 1X, I1, 4X, 2I5
Content: LA =5
LB = 14
U1 = Units for substrate density
= 1 for 1 / m**3
= 2 for 1 / cm**3
= 3 for 1 / mm**3
= 4 for 1 / ft**3
= 5 for 1 / in**3
IFUNC = Cooling rate function index if a positive number, for instantaneous nucleation
= Temperature function index if a negative number, for continuous nucleation
( 5, 15 ) Data Set - Lamellar Spacing
Input: LA, LB, U1, INDEX, ICOOL

Format: 2I2, 1X, I1, 4X, 2I5
Content: LA =5
LB = 15
U1 = Units for lamellar spacing
= 1 for m
= 2 for cm
= 3 for mm
= 4 for ft
= 5 for in
ICOOL = Cooling rate function index
( 5, 16 ) Data Set - Equiaxed Dendrite Micromodel

Input: LA, LB, U1, MAT, I1, I2, I3, I4, I5, GT, C0
Format: 2I2, 1X, I1, 4X, 6I5, 2E15.0
Content: LA =5
LB = 16
U1 = Units for Gibbs-Thompson coefficient
= 1 for m * K
= 2 for cm * K
= 3 for mm * K
= 4 for ft * F
= 5 for in * F
I1 = Index to Data Set ( 5, 10 )
GT = Gibbs-Thompson coefficient
C0 = Initial alloy composition
( 5, 17 ) Data Set - Coupled/Metastable Eutectic Growth Micromodel Instantaneous or Continuous Nucleation

Input: LA, LB, U1, U2, U3, MAT, I1, I2, I3, I4, GC, MGC, SMP, CCR, EC
Format: 2I2, 1X, 3I1, 2X, 5I5, 5E15.0
Content: LA =5
LB = 17
U1 = Units for growth constants
= 1 for m / sec / K**2
= 2 for cm / sec / K**2
= 3 for mm / sec / K**2
= 4 for ft / sec / F**2
= 5 for in / sec / F**2
= 6 for m / min / K**2
= 7 for cm / min / K**2
= 8 for mm / min / K**2
= 9 for ft / min / F**2
= 10 for in / min / F**2
U2 = Units of temperature for solvent melting point
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
U3 = Units for critical cooling rate for transition
= 1 for K / sec
= 2 for C / sec
= 3 for F / sec
= 4 for R / sec
= 5 for K / min
= 6 for C / min
= 7 for F / min
= 8 for R / min
GC = Stable growth constant
MGC = Metastable growth constant
SMP = Solvent melting point
CCR = Critical cooling rate for transition

EC = Eutectic composition
( 5, 18 ) Data Set - Eutectic Ductile Iron Micromodel

Input: LA, LB, MAT, I1, I2
Format: 2I2, 1X, 5X, 3I5
Content: LA =5
LB = 18
( 5, 19 ) Data Set - Eutectoid Ductile Iron Micromodel
Input: LA, LB, MAT, I1, I2

Content: LA =5
LB = 19
( 5, 20 ) Data Set - Eutectic Grey/White Iron Micromodel
Input: LA, LB, U1, MAT, I1, CCR

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 20
U1 = Units for critical cooling rate for transition
= 1 for K / sec
= 2 for C / sec
= 3 for F / sec
= 4 for R / sec
= 5 for K / min
= 6 for C / min
= 7 for F / min
= 8 for R / min
CCR = Critical cooling rate for grey to white transition
( 5, 21 ) Data Set - Eutectoid Grey Iron Micromodel
Input: LA, LB, MAT, I1

Content: LA =5
LB = 21
( 5, 22 ) Data Set - Peritectic Transformation Micromodel

Input: LA, LB, U1, MAT, I1, I2, I3, I4, I5, I6, I7, GT, C0, EC, RFS
Format: 2I2, 1X, I1, 4X, 8I5, 4E15.0
Content: LA =5
LB = 22
U1 = Units for Gibbs-Thompson coefficient
= 1 for m * K
= 2 for cm * K
= 3 for mm * K
= 4 for ft * F
= 5 for in * F
I2 = Index to Data Set ( 5, 11 ) for solid forming partition coefficient
I3 = Index to Data Set ( 5, 11 ) for solid reacting partition coefficient
I4 = Index to Data Set ( 5, 12 ) for liquid diffusivity
I5 = Index to Data Set ( 5, 12 ) for solid forming diffusivity
I6 = Index to Data Set ( 5, 12 ) for solid reacting diffusivity
GT = Gibbs-Thompson coefficient
C0 = Alloy composition
EC = Eutectic composition
RFS = Reacting solid fraction
( 5, 23 ) Data Set - Solid State Transformation Micromodels

Input: LA, LB, MAT, CO
Format: 2I2, 1X, 5X, I5, E15.0
Content: LA =5
LB = 23
CO = Alloy composition
( 5, 24 ) Data Set - Scheil Micromodel

Input: LA, LB, U1, U2, MAT, I1, I2, I3, FT, SMP, C0
Format: 2I2, 1X, 2I1, 3X, 4I5, 3E15.0
Content: LA =5
LB = 24
U1 = Units for final temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
U2 = Units of temperature for solvent melting point
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
FT = Final temperature
SMP = Solvent melting point
C0 = Alloy composition
( 5, 40 ) Data Set - Carreau-Yasuda Non-Newtonian Viscosity
Input: LA, LB, U1, U2, U3, MAT, ITEM0, ITEMI, ITEML, ITEMP, ITEMY, VIS0, VISI, PHASE, POWER,
YASUDA

Format: 2I2, 1X, 3I1, 3X, 6I5, 5E15.0

Content: LA =5
LB = 40
U1 = Units for viscosity at zero shear rate
= 2 for N - sec / m**2
= 3 for centpoise
= 4 for poise
U2 = Units for viscosity at infinite shear rate
= 2 for N - sec / m**2
= 3 for centpoise
= 4 for poise
U3 = Units for time
= 1 for sec
= 2 for min
ITEM0 = Temperature function index for VIS0
ITEMI = Temperature function index for VISI
ITEML = Temperature function index for PHASE
ITEMP = Temperature function index for POWER
ITEMY = Temperature function index for YASUDA
VIS0 = Zero shear rate viscosity
VISI = Infinite shear rate viscosity
PHASE = Phase shift coefficient
POWER = Power law coefficient
YASUDA = Yasuda coefficient
( 5, 41 ) Data Set - Filter data
Input: LA, LB, U1, U2, MAT, ITIME, ITEMP, VOIDF, SAREA, HTC
Format: 2I2, 1X, 2I1, 3X, 3I5, 3E15.0
Content: LA =5
LB = 41
U1 = Units for specific surface area (area/volume)
= 1 for 1 / meters
= 2 for 1 / centimeters
= 3 for 1 / millimeters
= 4 for 1 / feet
= 5 for 1 / inches
U2 = Units for fluid-filter heat transfer coefficient
= 1 for W / m**2 / K
= 2 for cal / cm**2 / C / sec
= 3 for cal / mm**2 / C / sec
= 4 for Btu / ft**2 / F / sec
= 5 for Btu / in**2 / F / sec
= 6 for cal / cm**2 / C / min
= 7 for Btu / ft**2 / F / min
= 8 for Btu / in**2 / F / min
ITIME = Time function index for HTC
ITEMP = Temperature function index for HTC
VOIDF = Void fraction of the filter
SAREA = specific surface area of the filter

HTC = Fluid-filter interfacial heat transfer coefficient
( 5, 50 ) Data Set - Magnetic permeability data
Input: LA, LB, U1, MAT, ITEMP, MAGP

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 50
U1 = Units for magnetic permeability
= 1 for Henry / meter
= 2 for Henry / centimeter
= 3 for Henry / millimeter
= 4 for Henry / feet
= 5 for Henry / inch
ITEMP = Temperature function index for MAGP
MAGP = Baseline or constant magnetic permeability
( 5, 51 ) Data Set - Electrical conductivity data
Input: LA, LB, U1, MAT, ITEMP, ECON

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 51
U1 = Units for electrical conductivity
= 1 for 1 / ( ohm-meter )
= 2 for 1 / ( ohm-centimeter )
= 3 for 1 / ( ohm-millimeter )
= 4 for 1 / ( ohm-feet )
= 5 for 1 / ( ohm-inch )
ITEMP = Temperature function index for ECON
ECON = Baseline or constant electrical conductivity

( 5, 60 ) Data Set - Elastic Modulus
Input: LA, LB, U1, MID, ITEMP, ELAST

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 60
U1 = Units for elastic modulus
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 6 for dyne / cm**2
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
MID = Material id number
ITEMP = Temperature function index for ELAST
ELAST = Baseline or constant elastic modulus
( 5, 61 ) Data Set - Poisson ratio
Input: LA, LB, MID, ITEMP, POISR

Format: 2I2, 1X, 4X, 2I5, E15.0
Content: LA =5
LB = 61
ITEMP = Temperature function index for POISR
POISR = Baseline or constant poisson ratio
( 5, 62 ) Data Set - Thermal expansion coefficient
Input: LA, LB, U1, MID, ITEMP, THEXP

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 62
U1 = Units for thermal expansion coefficient
= 1 for 1 / Kelvin
= 2 for 1 / Celsius
= 3 for 1 / Fahrenheit
= 4 for 1 / Rakine
ITEMP = Temperature function index for THEXP
THEXP = Baseline or constant thermal expansion coeffient
( 5, 63 ) Data Set - Yield stress
Input: LA, LB, U1, MID, ITEMP, YIELD

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 63
U1 = Units for yield stress
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
ITEMP = Temperature function index for YIELD
YIELD = Baseline or constant yield stress
( 5, 64 ) Data Set - Hardening Parameter
Input: LA, LB, U1, MID, ITEMP, HARD

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 64
U1 = Units for hardening
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
ITEMP = Temperature function index for HARD
HARD = Baseline or constant hardening
( 5, 65 ) Data Set - Hardening exponent
Input: LA, LB, MID, ITEMP, HARDE

Format: 2I2, 1X, 4X, 2I5, E15.0
Content: LA =5
LB = 65
ITEMP = Temperature function index for HARDE
HARDE = Baseline or constant hardening exponent

( 5, 66 ) Data Set - Visco power coefficient
Input: LA, LB, MID, ITEMP, VPOW

Format: 2I2, 1X, 4X, 2I5, E15.0
Content: LA =5
LB = 66
ITEMP = Temperature function index for VPOW
VPOW = Baseline or constant visco power coefficient
( 5, 67 ) Data Set - Fluidity
Input: LA, LB, U1, MID, ITEMP, FLUID

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =5
LB = 67
U1 = Units for fluidity
= 1 for 1 / seconds
= 2 for 1 / minutes
ITEMP = Temperature function index for FLUID
FLUID = Baseline or constant fluidity
( 6, 0 ) Data Set - Neumann boundary conditions, pointer data
Input: LA, LB, IEL, FACE, INDEX, IFLAG

Content: LA =6
LB =0
FACE = Element face number ( see Note A )
IFLAG = 1 if face participates in view factor calculations
= 0 otherwise or if element is 1D
( 6, 1 ) Data Set - Neumann boundary conditions, supplementary data
Input: LA, LB, U1, U2, U3, INDEX, ITIMQ, ITIMH, ITIME, ITIMT,
ITEMH, ITEME, Q, H, EPS, TA
Format: 2I2, 1X, 3I1, 2X, 7I3, 4E12.0
Content: LA =6
LB =1
U1 = Units for heat flux
= 1 for W / m**2
= 2 for cal / cm**2 / sec
= 3 for cal / mm**2 / sec
= 4 for Btu / ft**2 / sec
= 5 for Btu / in**2 / sec
= 6 for cal / cm**2 / min
= 7 for Btu / ft**2 / min
= 8 for Btu / in**2 / min
U2 = Units for heat transfer coefficient
= 1 for W / m**2 / K
U3 = Units for ambient temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
INDEX = Corresponds to INDEX in set ( 6, 0 )
ITIMQ = Time function index for Q
ITIMH = Time function index for H
ITIME = Time function index for EPS
ITIMT = Time function index for TA
ITEMH = Temperature function index for H
ITEME = Temperature function index for EPS
Q = Specified heat flux
H = Convection heat transfer coefficient
EPS = Epsilon for radiative heat transfer
TA = Ambient temperature
( 6, 2 ) Data Set - Coincident node information

Input: LA, LB, IEL1, FACE1, IEL2, FACE2, IH
Format: 2I2, 1X, I7, I5, I7, 2I5
Content: LA =6
LB =2
IEL1 = Element 1
FACE1 = Coincident face of element 1 ( see Note A )
IEL2 = Element 2
FACE2 = Coincident face of element 2 ( see Note A )
IH = Pointer to Data Set ( 6, 3 )
Note: The temperature of the face of element 1 is used in determining a value from the temperature function.

( 6, 3 ) Data Set - Interface heat transfer coefficients
Input: LA, LB, U1, INDEX, TIME, TEMP, H

Format: 2I2, 1X, I1, 4X, 3I5, E15.0
Content: LA =6
L1 =3
U1 = Units for heat transfer coefficient
= 1 for W / m**2 / K
INDEX = Corresponds to IH in Data Set ( 6, 2 )
TEMP = Temperature function number
H = Value of interface heat transfer coefficient
( 6, 4 ) Data Set - Enclosure faces for view factor radiation model
Input: LA, LB, INDEX1, INDEX2, NODE1, ... NODE4

Format: 2I2, 1X, 2I5, 4I7
Content: LA =6
LB =4
INDEX1 = Index of temperature and emissivity data in Data Set ( 6, 6 )
INDEX2 = Index of velocity data in Data Set ( 6, 5 )
NODE1, = Connectivity in bar, triangular, or quadrilateral face
...NODE*
( 6, 5 ) Data Set - Velocity data for moving enclosure faces or solid elements
Input: LA, LB, U1, INDEX, TIME, U, V, W

Format: 2I2, 1X, I1, 4X, 2I5, 3E15.0
Content: LA =6
LB =5
U1 = Units for enclosure velocity
= 1 for meters / sec
= 2 for centimeters /sec
= 3 for mm / sec
= 4 for feet / sec
= 5 for inches / sec
= 6 for meters / min
= 7 for centimeters /min
= 8 for feet / min
= 9 for inches / min
INDEX = Corresponds to INDEX2 in set ( 6, 4 )
U,V,W = X, Y, Z components of velocity
( 6, 6 ) Data Set - Temperature and emissivity data for enclosure faces
Input: LA, LB, U1 , INDEX, TIME, TEMP, FATEM, EPS

Format: 2I2, 1X, I1, 4X, 3I5, 2E15.0
Content: LA =6
LB =6
U1 = Units for face temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
INDEX = Corresponds to INDEX1 in set ( 6, 4 )
TIME = Time function number for FATEM
TEMP = Temperature function number for EPS
FATEM = Face temperature
EPS = Emissivity ( epsilon )
( 6, 7 ) Data Set - Multipoint constraints
Input: LA, LB, SLAVE, M1, W1, M2, W2, M3, W3, M4, W4
Format: 2I2, 1X, I5, 4(I5,E12.0)
Content: LA =6
LB =7
SLAVE = Number of node which is constrained
M1-M4 = Master nodes
W1-W4 = Weights associated with each master node
Note: A slave node may be constrained by 1 to 4 other nodes
( 6, 8 ) Data Set - Volumetric heat sources

Input: LA, LB, U1, IEL, TIME, TEMP, VALUE
Format: 2I2, 1X, I1, 4X, 3I5, E15.0
Content: LA =6
LB =8
U1 = Units for volumetric heat source
= 1 for W / m**3
= 2 for cal / cc / sec
= 3 for Btu / ft**3 / sec
= 4 for Btu / in**3 / sec
= 5 for cal / cc / min
= 6 for Btu / ft**3 / min
= 7 for Btu / in**3 / min
TEMP = Temperature function number
VALUE = Value of volumetric heat source
( 6, 9 ) Data Set - Linked Periodic Node List

Input: LA, LB, M1, N1, I1, M2, N2, I2, M3, N3, I3, M4, N4, I4
Contents: LA =6
LB =9
M1-M4 = Node in the first periodic region
N1-N4 = Node in the second periodic region, associated with M1-M4
I1-I4 = Periodic index pointing to Data Sets ( 4 6 ) and/or ( 4 7 )
( 6, 10 ) Data Set - Symmetry boundary condition
Input: LA, LB, IEL, FACE


Content: LA =6
LB = 10
FACE = Element face number ( see Note A )
( 6, 11 ) Data Set - Vent boundary condition
Input: LA, LB, U1, U2, U3, U4, NODE, ITIME, P_EXIT, DIAM, ROUGH, LENGTH
Format: 2I2, 1X, 4I1, 1X, 2I7, 4E15.0
Content: LA =6
LB = 11
U1 = Units for pressure
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
U2,U3,U4 = Units of length for DIAM, ROUGH, and LENGTH
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
NODE = Casting side node number where vent is attached
ITIME = Time function index for P_EXIT
P_EXIT = Pressure at exit of vent
DIAM = Vent diameter
ROUGH = Vent surface roughness
LENGTH = Vent equivalent length
( 6, 12 ) Data Set - Gas Injection Boundary Condition

Input: LA, LB, U1, NODE, TIME, PRES, MDOT
Format: 2I2, 1X, I1, 4X, 3I5, E15.0
Content: LA =6
LB = 12
U1 = Units for mass flux
= 1 kg / sec
= 2 g / sec
= 3 lb / sec
= 4 kg / min
= 5 g / min
= 6 lb / min
NODE = Node that marks the location of the injection site
TIME = Time function number modifying MDOT
PRES = Pressure function number modifying MDOT
MDOT = Gas injection mass flow rate
( 6, 13 ) Data Set - Virtual Mold Data
Input: LA, LB, U1, ELEM, FACE, MAT, GEOM, IHTC, PT

Format: 2I2, 1X, I1, 2X, 5I5, E15.0
Content: LA =6
L1 = 13
U1 = Units of length for penetration thickness
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
ELEM = Element number
FACE = Face number
MAT = Material id number, pointing to Data Set ( 3 1 )
GEOM = Geometry type
= 1 for slab
= 2 for cylinder
= 3 for spherical
IHTC = Interface heat transfer pointing to Data Set ( 6 3 )
PT = Penetration thickness of mold
( 6, 15 ) Data Set - Surface load faces
Input: LA, LB, ELEM, FACE, INDEX

Content: LA =6
L1 = 15
FACE = Face number
INDEX = Pointer to Data Set ( 6 16 )
( 6, 16 ) Data Set - Surface load data
Input: LA, LB, U1, INDEX, ITIME, XLOAD, YLOAD ZLOAD

Format: 2I2, 1X, I1, 2X, 2I5, 3E15.0
Content: LA =6
L1 = 16
U1 = Units for surface load
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
INDEX = Data set index
ITIME = Time function index for surface load
XLOAD, = Components of the surface load
YLOAD,
ZLOAD

( 6, 17 ) Data Set - Point load
Input: LA, LB, U1, NODE, ITIME, XLOAD, YLOAD, ZLOAD

Format: 2I2, 1X, I1, 2X, 2I5, 3E15.0
Content: LA =6
L1 = 17
U1 = Units for point load
= 1 for dynes
= 2 for Newtons
= 3 for lbs
ITIME = Time function index for point load
XLOAD, = Components of the point load
YLOAD,
ZLOAD
( 6, 18 ) Data Set - Non-aligning interface
Input: LA, LB, U1, INDEX, MID1, MID2, IHTC, TOL1, TOL2
Format: 2I2, 1X, I1, 2X, 4I5, 2E15.0
Content: LA =6
L1 = 18
U1 = Units for TOL1 and TOL2
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
INDEX = Non-aligning interface index
MID1 = Material id 1
MID2 = Material id 2
IHTC = Pointer to Data Set ( 6 3 )
TOL1 = In-plane tolerance
TOL2 = Perimeter tolerance
( 6, 19 ) Data Set - Fluid momentum sources
Input: LA, LB, U1, ELEM, ITIME, XMOM, YMOM, ZMOM

Format: 2I2, 1X, I1, 2X, 2I5, 3E15.0
Content: LA =6
L1 = 19
U1 = Units for momentum source
= 1 for Newton / cubic meter
= 2 for dyne / cubic centimeter
= 3 for lb / cubic feet
= 4 for lb / cubic inch
ITIME = Time function for the momentum source
XMOM, = Components of the momentum source
YMOM,
ZMOM
( 6, 20 ) Data Set - Free surface heat flux
Input: LA, LB, MID, INDEX

Content: LA =6
L1 = 20
INDEX = Pointer to Data Set ( 6 1 )
( 6, 21 ) Data Set - Fluid mass source
Input: LA, LB, U1, U2, U3, INDEX, TIMT, TIMS, TIMX, TIMY, TIMZ,
TEMP, MDOT, X, Y, Z
Format: 2I2, 1X, 3I1, 2X, 6I5, 5E12.0
Content: LA =6
L1 = 21
U1 = Units for source temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
U2 = Units for source mass flow rate
= 1 for Kg / sec
= 2 for g / sec
= 3 for lb / sec
= 4 for Kg / min
= 5 for g / min
= 6 for lb / min
U3 = Units of the coordinates X, Y, Z
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
INDEX = Fluid source index
TIMT = Time function for the source temperature
TIMS = Time function for the source mass flow rate
TIMX, = Time function for the source position
TIMY,
TIMZ
TEMP = Temperature of the source
MDOT = Mass flow rate of the source
X, = Source position
Y,
Z

( 6, 22 ) Data Set - Current Density
Input: LA, LB, U1, MID, ITIME, CURRENT

Format: 2I2, 1X, I1, 2X, 2I5, E12.0
Content: LA =6
L1 = 22
U1 = Units for current density
= 1 for amps / ( meters **2 )
= 2 for amps / ( centimeters ** 2 )
= 3 for amps / ( millimeters ** 2 )
= 4 for amps / ( feet ** 2 )
= 5 for amps / ( inches ** 2 )
ITIME = Time function for current density
CURRENT = current density
( 7, 0 ) Data Set - Dirichlet B.C. - Fixed Temperature
Input: LA, LB, U1, NODE, TIME, FIXVAL

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB =0
U1 = Units for fixed temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
NODE = Node number
FIXVAL = Value of fixed temperature
( 7, 1 ) Data Set - Dirichlet B.C. - Fixed U Velocity
Input: LA, LB, U1, NODE, INDEX, FIXVAL
Format: 2I2, 1X, I1, 4X, 2I5, E15.0

Content: LA =7
LB =1
U1 = Units for fixed velocity
= 1 for m / sec
= 2 for cm / sec
= 3 for mm / sec
= 4 for ft / sec
= 5 for in / sec
= 6 for m / min
= 7 for cm / min
= 8 for ft / min
= 9 for in / min
NODE = Node number
FIXVAL = Value of fixed velocity
( 7, 2 ) Data Set - Dirichlet B.C. - Fixed V Velocity

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB =2
= 1 for m / sec
= 2 for cm / sec
= 3 for mm / sec
= 4 for ft / sec
= 5 for in / sec
= 6 for m / min
= 7 for cm / min
= 8 for ft / min
= 9 for in / min
NODE = Node number
( 7, 3 ) Data Set - Dirichlet B.C. - Fixed W Velocity

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB =3
= 1 for m / sec
= 2 for cm / sec
= 3 for mm / sec
= 4 for ft / sec
= 5 for in / sec
= 6 for m / min
= 7 for cm / min
= 8 for ft / min
= 9 for in / min
NODE = Node number

( 7, 4 ) Data Set - Dirichlet B.C. - Fixed Pressure

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB =4
U1 = Units for fixed pressure
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
NODE = Node number
FIXVAL = Value of fixed pressure
( 7, 5 ) Data Set - Dirichlet B.C. - Fixed turbulence intensity
Input: LA, LB, NODE, ITIME, INTENS

Format: 2I2, 5X, 2I5, E15.0
Content: LA =7
LB =5
NODE = Node number
ITIME = Time function number for turbulence intensity
INTENS = Value of turbulence intensity as a fraction
Note: The turbulence kinetic energy at a prescribed node is calculated as
k = 0.5 * ( INTENS **2 ) * ( u**2 + v**2 + w**2 ).
( 7, 6 ) Data Set - Dirichlet B.C. - Fixed turbulence length scale
Input: LA, LB, U1, NODE, ITIME, LENGTH

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB =6
U1 = Units for turbulence length scale
= 1 for meters
= 2 for centimeters
= 3 for millimeters
= 4 for feet
= 5 for inches
NODE = Node number
ITIME = Time function number for turbulence length scale
LENGTH = Value of turbulence length scale
Note: The corresponding turbulence dissipation rate is calculated as
e = CMU * k**1.5 / LENGTH.
U1 CMU = .09 by default, but can be modified in the prefixp.dat file.
( 7, 7 ) Data Set - Dirichlet B.C. - Additional Information
Input: LA, LB, INDEX, TIME, PRES, FILLIM

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB =7
INDEX = Corresponds to INDEX in Data Sets ( 7, 1 ), ( 7, 2 ), and ( 7, 3 )
PRES = Pressure function number
FILLIM = Percentage of volume filled before stopping inlet flow
( 7, 8 ) Data Set - Rotating nodes
Input: LA, LB, NODE

Format: 2I2, 5X, I7
Content: LA =7
LB =8
NODE = Node number
Note: Nodes in this list will be given the angular velocity as specified in the 4 8 cards. If no 7 8 cards are used,
then the no-slip nodes will be given the angular velocity
( 7, 10 ) Data Set - Dirichlet B.C. - Fixed X displacement

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB = 10
U1 = Units for fixed displacement
= 1 for meter
= 2 for centimeter
= 3 for millimeter
= 4 for feet
= 5 for inch
NODE = Node number
FIXVAL = Value of fixed X displacement
( 7, 11 ) Data Set - Dirichlet B.C. - Fixed Y displacement

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB = 11
= 1 for meter
= 2 for centimeter
= 3 for millimeter
= 4 for feet
= 5 for inch
NODE = Node number
FIXVAL = Value of fixed Y displacement

( 7, 12 ) Data Set - Dirichlet B.C. - Fixed Z displacement

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB = 12
= 1 for meter
= 2 for centimeter
= 3 for millimeter
= 4 for feet
= 5 for inch
NODE = Node number
FIXVAL = Value of fixed Z displacement
( 7, 13 ) Data Set - Dirichlet B.C. - Fixed magnetic potential

Format: 2I2, 1X, I1, 4X, 2I5, E15.0
Content: LA =7
LB = 13
U1 = Units for fixed magnetic potential
= 1 for Weber / meter
= 2 for Weber / centimeter
= 3 for Weber / millimeter
= 4 for Weber / feet
= 5 for Weber / inch
NODE = Node number
FIXVAL = Value of fixed magnetic potential
Note: The magnetic potential is usually set to zero in the far field.
( 8, 0 ) Data Set - Non-uniform I.C. - Temperature
Input: LA, LB, U1, NODE, TIC

Format: 2I2, 1X, I1, 4X, I5, E15.0
Content: LA =8
LB =0
U1 = Units for non-uniform initial temperature
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
NODE = Node number
TIC = Initial temperature for NODE
( 8, 1 ) Data Set - Non-uniform I.C. - U Velocity
Input: LA, LB, U1, NODE, VIC

Format: 2I2, 1X, I1, 4X, I5, E15.0
Content: LA =8
LB =1
U1 = Units for non-uniform initial velocity
= 1 for m / sec
= 2 for cm / sec
= 3 for mm / sec
= 4 for ft / sec
= 5 for in / sec
= 6 for m / min
= 7 for cm / min
= 8 for ft / min
NODE = Node number
VIC = Initial u velocity for NODE
( 8, 2 ) Data Set - Non-uniform I.C. - V Velocity

Format: 2I2, 1X, I1, 4X, I5, E15.0
Content: LA =8
LB =2
= 1 for m / sec
= 2 for cm / sec
= 3 for mm / sec
= 4 for ft / sec
= 5 for in / sec
= 6 for m / min
= 7 for cm / min
= 8 for ft / min
NODE = Node number
VIC = Initial v velocity for NODE
( 8, 3 ) Data Set - Non-uniform I.C. - W Velocity

Format: 2I2, 1X, I1, 4X, I5, E15.0
Content: LA =8
LB =3
= 1 for m / sec
= 2 for cm / sec
= 3 for mm / sec
= 4 for ft / sec
= 5 for in / sec
= 6 for m / min
= 7 for cm / min
= 8 for ft / min
NODE = Node number
VIC = Initial w velocity for NODE

( 8, 4 ) Data Set - Non-uniform I.C. - Pressure
Input: LA, LB, U1, NODE, PIC

Format: 2I2, 1X, I1, 4X, I5, E15.0
Content: LA =8
LB =4
U1 = Units for non-uniform initial pressure
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
NODE = Node number
PIC = Initial pressure for NODE
( 9, X ) Data Set - Linear Temperature Function
Input: LA, LB, U1, CURVE, POINT, TEMP, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0
Content: LA =9
LB = 0 for conductivity
LB = 1 for film coefficient
LB = 2 for interface heat transfer
LB = 3 for face emissivity
LB = 4 for enclosure emissivity
LB = 5 for volumetric heat source
LB = 6 for density
LB = 7 for specific heat
LB = 8 for viscosity
LB = 9 for fraction solid
LB = 10 for surface tension
LB = 11 for partition coefficient
LB = 12 for diffusivity
LB = 13 for substrate density
LB = 14 for phase shift coefficient
LB = 15 for power law coefficient
LB = 16 for Yasuda coefficient
LB = 17 for filter interface heat transfer coefficient
LB = 18 for elastic modulus
LB = 19 for Poisson ratio
LB = 20 for thermal expansion
LB = 21 for yield stress
LB = 22 for strength parameter
LB = 23 for hardening parameter
LB = 24 for hardening exponent
LB = 25 for visco-plasticity power coefficient
LB = 26 for fluidity parameter
LB = 27 for magnetic permeability
LB = 28 for electrical conductivity
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
CURVE = Function number

TEMP = Temperature of the point
VALUE = Function value of the point
( 10, X ) Data Set - Time Function
Input: LA, LB, U1, CURVE, POINT, TIME, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0
Content: LA = 10
LB = 0 for specified heat flux
LB = 2 for ambient temperature
LB = 3 for fixed temperature
LB = 5 for enclosure face velocity
LB = 6 for enclosure face temperature
LB = 8 for fixed velocity
LB = 9 for fixed pressure
LB = 11 for maximum time step
LB = 12 for gas injection mass flux
LB = 13 for gravity vector rotation angle
LB = 14 for turbulence intensity
LB = 15 for turbulence characteristic length
LB = 16 for gas vent pressure
LB = 17 for angular velocity
LB = 18 for displacement
LB = 20 for surface load
LB = 21 for point load
LB = 22 for momentum source
LB = 23 for mass source flow rate
LB = 24 for mass source temperature
LB = 25 for mass source x position
LB = 26 for mass source y position
LB = 27 for mass source z position
LB = 28 for moving solid velocity
LB = 29 for current density
LB = 30 for magnetic potential
U1 = Units for time
= 1 for sec
= 2 for min
TIME = Time of the point

( 11, X ) Data Set - Quadratic Temperature Function
Input: LA, LB, U1, CURVE, POINT, TEMP, A, B, C

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0
Content: LA = 11
LB = 0 for conductivity
LB = 4 for enclosure emissivity
LB = 6 for density
LB = 7 for specific heat
LB = 8 for viscosity
LB = 9 for fraction solid
LB = 10 for surface tension
LB = 11 for partition coefficient
LB = 12 for diffusivity
LB = 14 for phase shift coefficient
LB = 15 for power law coefficient
LB = 16 for Yasuda coefficient
LB = 18 for elastic modulus
LB = 19 for Poisson ratio
LB = 20 for thermal expansion
LB = 21 for yield stress
LB = 22 for strength parameter
LB = 23 for hardening parameter
LB = 24 for hardening exponent
LB = 25 for visco-plasticity power coefficient
LB = 26 for fluidity parameter
LB = 27 for magnetic permeability
LB = 28 for electrical conductivity
= 1 for Kelvin
= 2 for Celsius
= 3 for Fahrenheit
= 4 for Rankine
TEMP = Temperature of the point
A = Constant coefficient
B = Coefficient of temperature
C = Coefficient of temperature squared
( 12, X ) Data Set - Pressure Function
Input: LA, LB, U1, CURVE, POINT, PRES, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0
Content: LA = 12
LB = 0 for density
LB = 1 for fixed velocity
LB = 2 for gas injection mass flux
U1 = Units for pressure
= 1 for N / m**2
= 2 for Pa
= 3 for KPa
= 4 for MPa
= 5 for bar
= 7 for atm
= 8 for psia
= 9 for lb / ft**2
PRES = Pressure of the point
( 13, X ) Data Set - Cooling Rate Function
Input: LA, LB, U1, CURVE, POINT, CRATE, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0
Content: LA = 13
LB = 1 for transformation temperature
LB = 2 for lamellar spacing
U1 = Units for cooling rate
= 1 for K / sec
= 2 for C / sec
= 3 for F / sec
= 4 for R / sec
= 5 for K / min
= 6 for C / min
= 7 for F / min
= 8 for R / min
CRATE = Cooling rate of the point

( 14, X ) Data Set - Concentration Function
Input: LA, LB, U1, CURVE, POINT, CONC, VALUE

Format: 2I2, 1X, I1, 4X, 2I5, 2E15.0
Content: LA = 14
LB = 0 for liquidus slope
U1 = Units for concentration
= 1 for 1 / m**3
= 2 for 1 / cm**3
= 3 for 1 / mm**3
= 4 for 1 / ft**3
= 5 for 1 / in**3
CONC = Cooling rate of the point
( 99, 0 ) Data Set - Terminator
Input: LA, LB
Format: 2I2
Content: LA = 99 to terminate the data file
LB =0
Note A:
Brick Element
Face Local Nodes
1 1 4 3 2
2 1 2 6 5
3 2 3 7 6
4 3 4 8 7
5 4 1 5 8
6 5 6 7 8

4 Node Tetrahedral Element
Face Local Nodes
1 1 3 2
2 2 4 1
3 2 3 4
4 4 3 1
Wedge Element
Face Local Nodes
1 1 3 2 -
2 4 5 6 -
3 1 2 5 4
4 2 3 6 5
5 3 1 4 6

Quadrilateral Element
Face Local Nodes
1 1 2
2 2 3
3 3 4
4 4 1
Triangle Element
Face Local Nodes
1 1 2
2 2 3
3 3 1

10 Node Tetrahedral Element
Face Local Nodes
1 1 3 2 7 6 5
2 2 4 1 9 8 5
3 2 3 4 6 10 9
4 4 3 1 10 7 8

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USERS MANUAL & TECHNICAL REFERENCE

ProCAST Users Manual & Technical Reference. Copyright 1996,

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PROCAST USERS MANUAL PAGE II

PROCAST USERS MANUAL PAGE III

USING INVERSE MODELING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 - 1

Section 8: Initial and Boundary Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 7

Section 9: The View Factor Radiation Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 10

Section 10: Finite Element Discretization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 12

Radial return mapping algorithm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 25

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Equiaxed Dendrite Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C - 50

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This Users Guide and Technical Reference is designed to explain how

Flexibility: ProCAST can provide both process-specific and analysis-

Graphical User Interface: ProCASTs graphical user interface has been

Database Facility: Database capabilities have been integrated into the

Results: Post-simulation processing is robust. ProCAST provides the

capability to extract and view a comprehensive range of contour and

Benefits: ProCAST provides the tools to help you build a quality

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and the view factors are automatically updated. ProCAST

PreCAST--performs pre-simulation processing by providing the

DataCAST--reads the problem definition data created by PreCAST,

ProCAST--simulates the casting process, performs the finite element

PostCAST--provides the post-simulation capability to view X-Y plots,

ViewCAST--provides the capability to view the results of the simulation.

MeshCAST--provides the capability to import geometries from

Outstanding fluid flow capabilities for casting simulations are

A unique method for calculating radiation view factors has been

Complex geometries may be generated using the multi-point

Accurately model the phase transformation of any alloy or pure metal,

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to the extent that the fraction solidified function has been

Specific technical capabilities of ProCAST include the following:

The path to follow to take advantage of these and other capabilities in

Step One: Load or create a model

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The solid mesh of the model should contain, as a minimum, the

These options and methods are described in detail in the Using

Step Two: Set-up the problem

Step Three: Check the model

Step Four: Run the simulation

Step Five: Extract the desired results

Step Six: View the results

Function banners allow you to move from one capability to another

F3 Zoom out by 10%

X Rotate about the x axis by 10%

Y Rotate about the y axis by 10%

Z Rotate about the z axis by 10%

CTRL+X Rotate about the x axis by -10%

CTRL+Y Rotate about the y axis by -10%

CTRL+Z Rotate about the z axis by -10%

SHIFT+X Rotate about the x axis by 30%

SHIFT+Y Rotate about the y axis by 30%

SHIFT+Z Rotate about the z axis by 30%

CTRL+SHIFT+X Rotate about the x axis by -30%

CTRL+SHIFT+Y Rotate about the x axis by -30%

CTRL+SHIFT+Z Rotate about the x axis by -30%