Anypre: A Pre-Processor of Anycasting

anyPRE
A Pre-Processor of AnyCasting
AnyCasting™ Advanced Casting Simulation Software 001

Table of Contents
anyPRE........................................................................................................................................................ 1
1 anyPRE Introduction .............................................................................................................. 6
1.1 AnyCasting Program ................................................................................................ 6
1.2 Work Flow ..................................................................................................................... 7
1.3 Input/Output Files ..................................................................................................... 8
2 User Interface............................................................................................................................ 9
2.1 Window Layout ........................................................................................................... 9
2.2 Mouse Instruction ...................................................................................................10
2.3 View Control/Adjustment ....................................................................................11
2.4 Menu & Toolbar .......................................................................................................14
2.5 Property Window .....................................................................................................24
3 Entity ...........................................................................................................................................27
3.1 Entity Overview .........................................................................................................27
3.2 Transform .....................................................................................................................29
3.3 Merge Entity...............................................................................................................30
3.4 Smash ............................................................................................................................30
3.5 Discontinuity ..............................................................................................................31
3.6 Entity Properties .......................................................................................................31
4 Measurement ..........................................................................................................................32
4.1 A Vertex based Measurement ...........................................................................32
5 Mesh Generation ...................................................................................................................33
5.1 Set Entity .....................................................................................................................33
5.2 Set Mold ......................................................................................................................34
5.3 Set Domain .................................................................................................................35
002 AnyCasting User Maunal / anyPRE

5.4 Build Uniform Mesh ...............................................................................................36
5.5 Build Variable Mesh ................................................................................................37
5.6 Import Mesh ..............................................................................................................39
5.7 Undo Meshing ..........................................................................................................39
5.8 Review Mesh Information ....................................................................................40
6 Overview of Simulation Conditions ..............................................................................41
6.1 Input Data ...................................................................................................................42
7 Basic Procedures....................................................................................................................43
7.1 Task Design .................................................................................................................43
7.2 Material Setting ........................................................................................................44
7.3 Initial and Domain Boundary Condition .......................................................47
7.4 Heat Transfer Model...............................................................................................48
7.5 Gate Condition ..........................................................................................................52
7.6 Gravity Force ..............................................................................................................54
8 Optional Module ...................................................................................................................55
8.1 Shrinkage Model ......................................................................................................55
8.2 Fluid Flow Model .....................................................................................................56
8.3 Microstructure Model ............................................................................................58
8.4 Segregation Model .................................................................................................61
8.5 Thixo Model ...............................................................................................................62
8.6 Oxide/Inclusion Model ..........................................................................................64
8.7 Cyclic Casting ............................................................................................................65
8.8 Back Pressure .............................................................................................................72
8.9 Vacuum/Air-Vent ......................................................................................................72
8.10 Gravity Tilting ..........................................................................................................73
8.11 Large Casting ..........................................................................................................74
8.12 Exothermic Powder ...............................................................................................76
8.13 Shot-Sleeve ..............................................................................................................77
8.14 Centrifugal Casting ...............................................................................................83
8.15 Particle Tracing .......................................................................................................84
8.16 Mold Erosion ...........................................................................................................84

8.17 Flow Tracking ..........................................................................................................85
8.18 Cast Iron ....................................................................................................................85
8.19 Core Gas ....................................................................................................................86
8.20 Gas Entrapment .....................................................................................................87
9 Set Instruments ......................................................................................................................88
9.1 Sensor ...........................................................................................................................88
9.2 Channel ........................................................................................................................90
9.3 Pouring Basin .............................................................................................................95
9.4 Stopper .........................................................................................................................96
9.5 Stalk................................................................................................................................97
9.6 Filter ...............................................................................................................................97
9.7 Exothermic Sleeve ...................................................................................................98
10 anySOLVER Launching Condition ............................................................................ 100
10.1 Solution Method ................................................................................................ 100
10.2 End/Output Condition ..................................................................................... 104
10.3 Run anySOLVER .................................................................................................. 106
11 Preference ........................................................................................................................... 107
11.1 Color......................................................................................................................... 107
11.2 Entity Color ........................................................................................................... 107
11.3 Unit ........................................................................................................................... 108
11.4 Database................................................................................................................. 108
11.5 Misc. ......................................................................................................................... 109
12 Convert ................................................................................................................................. 110
Microsoft Windows™ is a registered trademark of Microsoft Cooperation.

Copyright © 2001 AnyCasting Co., Ltd. All rights reserved

1
anyPRE Introduction
To perform numerical analysis, anyPRE requires mesh generation & simulation condition setting. Every nu-
merical analysis program includes a program called ‘pre-processor’ for setting mesh generation & simulation
condition. An ideal pre-processor must be able to check input geometry in high-definition graphics, as well as
conveniently and quickly set high-definition mesh generation & simulation condition. anyPRE can build finite
difference method (FDM) mesh based on the shape analyzed from CAD file and perform various CAD func-
tions. It also includes a function for setting simulation condition to launch anySOLVER.
1.1 AnyCasting Program
anyPRE, which is the pre-processor of AnyCasting, includes a function for generating FDM mesh by analyzing
CAD file, as well as setting simulation condition to launch anySOLVER. By using anyPRE, users can select the
work flow of simulation casting process, select materials, set boundary condition, set initial condition, set
gate condition, etc. In addition, users can set various device settings and models through its advanced func-
tion. Users can also use the CAD function of anyPRE to check or move/rotate various shapes.
anyPRE, which has been developed based on MS-Window, is a casting process-oriented

Features pre-processor to allow casting workers in the field to conveniently and easily use the program with
a minimum level of program knowledge.
User Interface
Menus and functions that are based on MS-Window allow users with basic personal computer knowledge to
easily perform various tasks.
Fast Meshing Algorithm

Builds hundreds to tens of millions meshes within a few seconds by using Surface Vector Tracking method.
When generating variable mesh, Smoothing Algorithm can be used to not only control mesh size effectively
but also increase the accuracy of simulation results.
High Quality Viewing

Enhances the comprehension of input geometry by using cross-section viewing, geometry viewing, meas-
urement and transparency adjustment functions.
Easy Setting of Simulation Condition

Casting process-oriented setting of simulation condition allows users to conveniently and easily use the
program even for those that are not experts on simulation programs

1.2 Work Flow
In anyPRE, simulation conditions to run anySOLVER are set after generating mesh by reading geometry file
(CAD file) or files created by anyPRE (GSCX file).
1) Import CAD File (STL file)
2) Build Mesh
① Define the properties of each entity
② Set mold
③ Select domain (simulation area)
④ Build uniform/variable mesh
3) Set Simulation Condition
4) Set Basic Simulation Procedure

① Determine the process and the scope of simulation
② Select material properties
③ Set initial temperature condition and wall (domain) boundary condition
④ Set heat transfer condition (heat transfer coefficient, coated material, etc.)
⑤ Set gate conditions
⑥ Set the direction of gravity
5) Set Optional Modules

① Select shrinkage model for shrinkage defect prediction
② Set fluid flow (turbulence/surface tension) model
③ Set microstructure prediction model
④ Set segregation prediction model
⑤ Select thixo-forming model
⑥ Set oxide/inclusion prediction model
⑦ Set the cyclic casting condition
⑧ Set vacuum/vent condition
⑨ Set back pressure condition
⑩ Set gravity tilt pour casting condition
⑪ Set large ingot condition
⑫ Set high pressure die casting sleeve condition (including plunger)
⑬ Set particle tracing condition
⑭ Set mold erosion condition
⑮ Set flow tracking condition

6) Set Instruments
① Install sensor at a particular location to check temperature, velocity, pressure, etc.
② Set cooling/heating channel
③ Set pouring basin
④ Set stopper condition
⑤ Set stalk condition
⑥ Set filter condition
7) Set the Launching Condition of anySOLVER

- Launch anySOLVER after setting/saving various conditions on how simulation will end and be saved.
1.3 Input/Output Files
Import&save CAD files to create *.gscx files that can be used in anyPRE. In addition, set various simulation
conditions such as mesh generation information & boundary conditions to create files needed to launch
anySOLVER.
[Input Files]
STL file: STL type files are commonly used in CAD programs to output various shapes created in
these programs. anyPRE generates mesh upon importing/reading these geometry files.
GSCX file: GSCX type files are created in anyPRE contain all of the information on the tasks performed
by user or information on CAD shape. These files are imported to begin new tasks or resume
prior tasks.
[Output Files]
Selecting ‘File/Save’ will save GSCX files during which MSHX, PRPX files needed to launch anySOLVER will
also be created.
Project.gscx File that contains the information on tasks performed by anyPRE
Project.mshx File that contains mesh information
Project.mif6x File that contains RealFlow (sub-divided)mesh information
Project.prpx File that contains simulation conditions
Project.xml File that contains information on analysis option
Project.pxm File that contains information on analysis condition

2
User Interface
The intuitive user interface of anyPRE allows anyone familiar with MS Windows to easily navigate through
and use the application. Thanks to its user-friendly design, all it requires is a few mouse clicks and simple
numerical entries.
2.1 Window Layout
anyPRE window mainly consists of the following five parts, and each window & toolbar can be customized.
① Menu & Toolbar

② Module Window: Window in which main functions have been categorized into groups
③ Main Window: Window that displays the results in graphics
④ Viewpoint Window: Window for controlling and adjusting the screen view
⑤ Property Window: Window that displays various types of information on each entity including its name,
color, size, volume and material. It displays the total number of entities and the total number of meshes
(number of meshes of each axis).

2.2 Mouse Instruction
1) Basic Instruction
Rotate: Left button click & drag
Pan: Middle button click & drag or Shift+ Left button click & drag
Zoom In/Out: Wheel spin or Ctrl+ Left button click & drag
2) View Quick Menu

Click right button when the mouse cursor is on top of a particular entity to display the menu of the entity.
When the cursor is on top of background, clicking right button will display the view menu.
3) Switch to Select Mode

During various tasks such as setting gate condition, performing measurements and setting sensor, pressing
the spacebar when these functions are activated will turn on/off the select mode. Rotation is not possible,
however, in the select mode.
4) View Cross-Section
Cross-section function becomes activated for a closer inside view when the mouse cursor is placed on top of
the four corners or the middle line of the plane while cross-section is turned on. Click the plane with the
mouse left button and drag it to the desired location.
5) Mouse Cursor
The followings are different cursor shapes according to the mouse mode.
Basic mode; rotate Zoom in specific area
Pan Select mode
Zoom in/out Activate cross-section
Rotate screen axis Drag cross-section

2.3 View Control/Adjustment
1) Basic Functions
Rotate: Left button click & drag
Pan: Middle button click & drag or Shift+ Left button click & drag
Zoom In/Out: Wheel spin or Ctrl+ Left button click & drag
Zoom In Selected Area: Select ‘View->Zoom Window’ or press hotkey ‘C’ + Left button click & drag (& drop)
Previous View: Select ‘View -> Previous View’ or press hotkey ‘V’
Reset View: Select ‘View -> Reset View’ or press hotkey 'R'
*Note
Press Esc to return to the basic mode (rotate).
2) Save Current User Viewpoint

Saving the current viewpoint of user can be useful when creating report or comparing the design changes
between two models.
Follow the below steps to save current viewpoint:
1. Select ‘View -> Viewpoints -> Add User View point(Alt+U)’ or click icon in Viewpoint Window
2. Enter the user name in dialogue window
3. User defined viewpoint is added as the last view point field
4. Select the added menu to apply the saved viewpoint to the current screen
Add User ViewPoint Add user viewpoint
Delete User ViewPoint Delete the current viewpoint selected
Load User ViewPoint Load saved file
Save User ViewPoint Create a file for the saved viewpoint
3) Rotate screen
Clicking direction button of Rotation Tool, User can rotate screen to desired angle.
Double clicking middle of Rotation Tool, User can set angle.

4) Change Projection Mode
The current screen projection mode can be changed by selecting ‘View -> Perspective/Isometric’
The Perspective Projection mode displays perspective. In the Orthographic / Isometric Projection mode, on
the other hand, all objects appear in the same size regardless of their locations.
Perspective Projection Orthographic Projection
5) Perpendicular Cross-Section
Cross-section can be moved by either entering coordinates/index from the Cross Section toolbar, using ‘Spin’
button or using mouse.
Follow the below steps when using mouse:
① Select ‘Cross-Section->Active’ to turn on cross-section.
② While cross-section is turned on, place the mouse cursor on top of the four corners or the middle line of the
plane, which will activate cross-section that will turn yellow.
③ Select the plane by continuously pressing the mouse left button and move to the desired location. Cross-section
with up to three directions (x,y,z) can be created.
▶ ▶ ▶
Cross-section plane is Plane is activated as it Grab the activated plane While pressing the left
turned on. turns yellow when the by pressing the left mouse button, move the
mouse cursor is placed on mouse button. plane.
top of the four corners or
the middle line of the
plane.

6) Free Cross-Section
To rotate cross-section by certain degrees, select ‘Cross Section->Free Mode’ or click icon from the
toolbar and press the left mouse button after placing the cursor on top of a corner of the cross-section to
rotate.
Place the cursor on top of the Rotate the cross-section while continuing to press the left mouse
cross-section edge. button, rotate the cross-section.
7) Set Background Color

Users can select background color and gradient background effect from the ‘File->Preference’ menu. Quick
menu is also displayed when the right mouse button is pressed while the mouse cursor is placed on back-
ground. The background color and gradient effect can be set.
Gradient effect is turned on
Background is in single color

2.4 Menu & Toolbar
1) Menu
File File
New Create a new file
Open Open *.gscx,*.gsc files
Close Close current project
Save Save current project
Save As Save current project in a different name
Save All Save all files associated with current project
Convert Convert old version file into new version file
Import Import CAD file (*.stl)
Export Export file
- To Image Save current screen into BMP or JPEG file
- Condition Template Save current simulation condition into GST file
Print Print current screen
Print Preview Preview the print of current screen
Print Setup Set various print options
Preference Set various configurations such as background color, database, unit, etc.
Recent File Display a list of recently opened files
Exit Close all windows and end the program
Entity Entity
Copy to Clipboard Copy the current screen to clipboard
Merge Merge selected entities (It activates only before Mesh is generated )
Priority (When mesh is being generated) Set the priority order of entities
Reverse Normal (All Entities) Reverse all surface entities of the model
Undo Undo the Translate , Rotate action performed
Mesh Mesh Generation

Set Entity Set entity properties
Set Mold Set the size & type of mold
Set Domain Set the domain size & symmetrical planes
Build Uniform Mesh Build uniform mesh
Build Variable Mesh Build variable mesh
Import Mesh Import built mesh
Undo Meshing Delete mesh / Certain parts of prior simulation condition settings are not saved
Mesh Information Display information on the size and number of meshes built

Simulation Simulation Condition Setup
Basic Procedure Set basic simulation conditions
- Task Design Select casting process & analysis scope
- Material Setting Select material
- Initial and Domain BC Set initial/boundary conditions
- Heat Transfer Model Set heat transfer coefficient & coating conditions
- Gate Condition Set gate conditions
- Gravity Force Set gravity force and direction
Optional Modules Advanced Simulation Condition Setup
- Shrinkage Model Set shrinkage model
- Fluid Flow Model Set advanced fluid flow (turbulence/surface tension) model
- Microstructure Model Set microstructure prediction model
- Segregation Model Set segregation model
- Thixo Model Set thixo-forming model
- Oxide/Inclusion Model Set oxide/inclusion prediction model
- Cyclic Casting Set cyclic casting conditions
- Back Pressure Set back pressure conditions
- Vacuum/Air-Vent Set vacuum/air-vent conditions
- Gravity Tilting Set gravity tilt pour casting conditions
- Large Casting Set large ingot casting conditions
- Exothermic Powder Set Exothermic Powder
- Shot-Sleeve Set high pressure casting sleeve conditions
- Centrifugal Casting Set centrifugal casting conditions
- Particle Tracing Set particle tracing conditions
- Mold Erosion Enable mold erosion activation
- Flow Tracking Enable melt flow tracking activation
- Cast Iron Set cast iron conditions
- Core Gas Set core gas conditions
- Gas Entrapment Set gas entrapment conditions

*Activation dependent upon the existence of corresponding
Set Instruments Various Instruments Setup
entity
- Sensor Set sensor

- Channel Set cooling/heating channel conditions
- Pouring Basin Set pouring basin conditions
- Stopper Set stopper conditions
- Stalk Set stalk conditions

- Filter Set filter conditions
- Exothermic Sleeve Set Exothermic Sleeve conditions
Launching Condition anySOLVER Launching Conditions Setup
- Solution Method Set the thermal flow simulation conditions of anySOLVER

- End/Output Condition Set solution end &result file output conditions
- Run Launch anySOLVER

Cross-Section Cross-Section
Active Activate cross-section view
Move Backward Move to the back of the cross-section plane
Move Forward Move to the front of the cross-section plane
Cross-Section YZ Set current plane to cross-section YZ(x-axis direction)
Cross-Section XZ Set current plane to cross-section XZ(y-axis direction)
Cross-Section XY Set current plane to cross-section XY (z-axis direction)
Flip Reverse the currently visible area around the cross-section
Section Plane Show/hide the plane for cross-section view
Section Only Show/hide outline only at cross-section
Section Grid Show/hide the grid of cross-section
Reset Reset cross-section to initial setting
Free Mode Rotate cross-section to desired direction
Measure Measure
Vertex Coordinate Measure the coordinates of a vertex
Distance between 2 Vertices Measure the distance between 2 vertices
Center of Segment Measure the center point of 2 vertices
3 Vertices Angle Calculate the angle between 2 straight lines composed of 3 vertices
3 Vertices Radius Calculate the radius of a circle composed of 3 vertices
Measuring Info To Clipboard Copy the measurement information to clipboard
Surface Area Displays the total surface area of all entities(except for automatically built mold)
Volume Displays the total volume of all entities (except for automatically built mold)

Measure Measure
Distance between 2 Vertices Measure the distance between 2 vertices
Center of Segment Measure the center point of 2 vertices
3 Vertices Angle Calculate the angle between 2 straight lines composed of 3 vertices
Measuring Info To Clipboard Copy the measurement information to clipboard
Displays the total surface area of all entities(except for automatically built
Surface Area
mold)
Volume Displays the total volume of all entities (except for automatically built mold)
View View
Perspective Switch current screen to perspective projection (with perspective)
Isometric Switch current screen to isometric projection (without perspective)
View Point Set viewer viewpoint (switch to isometric perspective)
- West (-x) Switch screen to -x direction
- East (+x) Switch screen to +x direction
- South (-y) Switch screen to -y direction
- North (+y) Switch screen to +y direction
- Backward (-z) Switch screen to -z direction
- Forward (+z) Switch screen to +z direction
- Add User Viewpoint Add user viewpoint
- Load Viewpoint Load a saved viewpoint file
- Save Viewpoint Save as a viewpoint file
Rotate Left Rotate 90 degrees to the left from the normal vector of current screen
Rotate Right Rotate 90 degrees to the right from the normal vector of current screen
Axial Rotate Rotate by certain degrees from the normal vector of current screen
View Mode
- Geometry Display entity in input geometry(CAD mode)
- Mesh Display entity in mesh mode
Render Mode Render Mode
- Surface with Edge Display the surface and edge of STL file
- Surface only Display only the surface of STL file
- Surface with Edge All Display the surface and all edges of STL file
- Edge Only Display only the edge of STL file
- Edge All Display all edges of STL file
- Vertex Only Display only the vertex of STL file
View Entity
- Cast Show/hide the Cast Entity
- Mold Show/hide the Mold
- Inserted Show/hide the Inserted
- Attached Show/hide the Attached
- Channel Show/hide the Channel
- Exothermic Show/hide the Exothermic
Select Rotation Center Set the center point of view rotation
Select Rotation Center Set the center point of view rotation
Reset Rotation Center Reset the center point of view rotation
Zoom In Zoom in screen
Zoom Out Zoom out screen
Zoom Window Zoom in selected area
Fit to Window Zoom in/out to fit current screen size
Previous View Return to previous view
Reset View Return to initial view
Spinning Spin all entities at a desired speed/direction
Fast Moving Turn on/off the current screen quick display function
Display Display
Axis Show/hide the lower right corner axis
World Axis Show/hide the auxiliary axis at 0,0,0
Auxiliary Axis Show/hide the center auxiliary axis
Entity Extent Display the extent of entity
Mold Extent Display the extent of mold
Domain Extent Display the extent of domain
Error Show/hide mesh error
Logo Show/hide the AnyCasting logo at the lower left corner
Text Show/hide entity, mesh number
Scale Show/hide scale (It activates only when Isometric View has been activated.)
Rotation Tool Show/hide Rotate Tool

Windows Windows
Full Screen Show/hide graphic window as full screen
New Window Open window with the same result of the current window
Cascade Arrange all open windows in staircase fashion
Tile Horizontal Arrange all open windows in horizontally non-overlapping tile fashion
Tile Vertical Arrange all open windows in vertically non-overlapping tile fashion
Arrange Icons Arrange all minimized windows
Viewpoint Window Show/hide viewpoint window
Property Window Show/hide property window
Module Window Show/hide module window
Status Bar Show/hide status bar window
Standard Show/hide standard toolbar window
Build Show/hide build toolbar window
Display Show/hide display toolbar window
Measure Show/hide measure toolbar window
View Show/hide view toolbar window
Section Show/hide section toolbar window
Help Help
Language Change language
Contents Display online help contents
About anyPRE Display anyPRE product name, version and website

2) Toolbar
Standard
New Create new file
Open Open *.gscx,*.gsc file
Save Save current project
Save all Save all files associated with current project
Print Print current screen
Print Preview Preview the print of current screen
Import Import CAD file (*.stl)
Export Export image file
Copy to Clipboard Copy current screen to clipboard
Module window Show/hide module window
Property window Show/hide property window
Viewpoint window Show/hide viewpoint window
Full Screen Switch to full screen mode
Text Show/hide entity / mesh number
About Display the casting name, version and website
Measure
2 Vertices Distance Measure the distance between 2 vertices
Center point of Segment Measure the center point of 2 vertices
Calculate the angle between 2 straight lines composed

3 Vertices Angle
of 3 vertices

View
Zoom In Zoom in screen
Zoom Out Zoom out screen
Zoom Window Zoom in selected area
Fit to Window Zoom in/out to fit current screen size
Previous View Return to previous view
Reset View Return to initial view
Spinning Spin all entities at a desired speed/direction
Axial Rotate Rotate by certain degrees from the normal vector of current screen
Rotate 90 degrees to the right from the normal vector of current

Rotate Right
screen
Rotate Left Rotate 90 degrees to the left from the normal vector of current screen
View Point Set viewer viewpoint (switch to isometric perspective)
Projection Mode Switch to projection mode
Geometry Mode Display entity in input geometry (CAD mode)
Mesh Mode Display entity in mesh mode
Turn on/off the function of quickly moving the entity at the current
Fast Moving
screen.
Cast Show/hide the Cast Entity
Mold Show/hide the Mold
Inserted Show/hide the Inserted
Attached Show/hide the Attached
Channel Show/hide the Channel
Exothermic Show/hide the Exothermic

Display
Entity Extent Turn on/off entity extent
Mold Extent Turn on/off mold extent
Domain Extent Turn on/off domain extent
Show Axis Show/hide the lower right corner axis
Show Auxiliary Axis Show/hide the center auxiliary axis
Rotation Tool Show/hide Rotate Tool
Cross-section ⓐ ⓑ ⓒ
Activate Cross-section Activate cross-section view
Move Backward Move to the back of the cross-section plane ( - direction)
Move Forward Move to the front of the cross-section plane ( + direction)
YZ Plane Set current plane to cross-section YZ(x-axis direction)
XZ Plane Set current plane to cross-section XZ (y-axis direction)
XY Plane Set current plane to cross-section XY (z-axis direction)
Show Section Plane Show/hide the plane for cross-section view
Show Section Only Show/hide outline only at cross-section
Show Grid Show/hide the grid of cross-section
Flip Reverse the currently visible area around the cross-section
Reset Reset cross-section to initial setting
Free Section Turn on/off free cross-section rotation function
ⓐ Coordinates of current cross-section
ⓑ Grid no. of current cross-section
ⓒ Number of grids of current setting

Mesh
Merge Entity Merge selected entities
Set Entity Set entity properties
Set Mold Set mold size & type
Set Domain Set the domain size & symmetrical planes
Uniform Mesh Build uniform mesh
Variable Mesh Build variable mesh
Import Mesh Import built mesh
Undo Meshing Delete built mesh

2.5 Property Window
Property window consists of 5 tabs –entity, gate, sensor, contact and vent – that clearly display their respec-
tive properties.
1) Entity Properties
The entity tab displays various types of information on entity including its name, color, size, volume and
material. Entity properties can be changed by double-clicking items from the list or selecting them through
Ctrl, Shift mouse click followed by right mouse button click menu.
2) Gate Properties
The gate tab displays various types of information on gate including the number, direction, area, flow con-
dition and thermal condition.
Display items are as follow.

No Gate number
Name Gate name (default: Gate_#)
Direction Melt flow direction
Area Cross-sectional area of gate
Flow Condition Melt pouring condition at the selected gate
Thermal Condition1 Pouring temperature
Thermal Condition2 Boundary condition at the gate after melt filling

3) Sensor Properties
The sensor tab displays various types of information on installed sensor including its number, mesh index and
coordinates.
Visible Show/hide the sensor
No Sensor no.
Sensor Sensor name (default: Sensor_#)
Installed at Entity of installed sensor
Coordinate Coordinate of sensor
Index Mesh number of sensor location
ID Sensor ID
4) Contact Property
The contact tab displays the information on the contact surface between two entities. Selecting interface
from the list will highlight two entities on the screen.
Name Entity name
Type Entity property
ID Entity ID
HTC Heat transfer coefficient
Area Area of contact
Heat transfer coefficient and/or coating

conditions can be set by double-clicking
items from the list or selecting them through
Ctrl, Shift mouse click.

5) Pin Vent Properties
Selecting pin vent from the list will highlight it on the screen.
Visible Show/hide
No Pin vent number
Name Pin vent name
Coordinate Coordinate of pin vent
Area(mm^2) Area of pin vent
Radius Radius of pin vent
*Note
Use to set Pin Vent except for Vacuum Vent (inner pressure removal effect)
- Switch the mouse to Select Mode by pressing the spacebar
- And click mouse to set Pin Vent location

3
Entity
An entity, which is the smallest unit composing a casting system in anyPRE, is created when importing CAD
file or automatically generated within the system (in the case of box/shell mold).
3.1 Entity Overview
1) Entity Properties
To build mesh or input simulation conditions, respective properties of all entities must be defined.
CAST Entire domain in which melt flows (e.g., casting, gate, overflow)
- CAVITY Casting product
- INGATE Ingate
- RUNNER Runner
- SLEEVE High pressure die casting sleeve
- BASIN Pouring basin
- OVERFLOW Overflow
- STOPPER Stopper
- STALK Stalk
- GATE Gate located inside the mold
- FILTER Filter
MOLD Mold
INSERTED Materials inserted into the casting(e.g. core)
ATTACHED Materials attached outside the casting or mold (e.g. chill)
CHANNEL Cooling/heating channel
EXOTHERMIC Exothermic sleeve

2) Viewing Entities
The render mode of each entity is as follows. The render mode can be changed through the two methods
described below.
1. Select the Render Mode by clicking right mouse button when the cursor is placed on top of entity.
2. Changes can be made from the Set Entity Window.
Edge All Geometry Mesh Mode Surface Surface only Edge only
Mode with Edge All
3) Using the Right Mouse Button Menu
The entity menu is displayed when the mouse cursor is placed on top of the entity. Entity menu functions are
as follow.
Entity name, properties
Select Surface, Edge, Edge All or Vertex
Change entity color
Adjust entity transparency

Hide the entity (Show entity: check the ‘Visible’ field from
the entity window)
Define entity properties
Move/Rotate
Smash merged entity
Delete selected entity
Export the selected entity as a STL file
Change the entity geometry while maintaining its properties
Show all entities

Hide all entities
Reverse show entity mode
Entity properties (volume, area, weight & initial condition)

4) Selecting Multiple Entities
To change entity properties, select multiple entities through Ctrl + mouse click or Shift + mouse click from
Property Window followed by the right mouse button click.
3.2 Transform
After placing mouse cursor on top of an entity to translate/rotate, click the right mouse button and select
‘Transform’ from the entity menu.
1) Translate
Relative: Move the selected entity in the x, y, z direction by the relative displacement.
Vector: Move the current entity by the displacement of the two vertices selected with the mouse.
*Press the Esc key to return to basic mode (rotate).
2) Rotate
Axis: Select rotational axis
Origin: Center coordinates of rotational axis
Angle: Enter rotational angle

3) Mirror
Mirror the selected entity centering on YZ, XZ, XY side.
4) Reverse Normal
Reverse the triangle direction of the selected entity.
(When Entity direction is reversed, Mesh is not generated.)
5) Undo
After placing mouse cursor on top of an entity to perform the ‘Undo’ function, click the right mouse button to
display the Quick Menu and select ‘Transform ->Undo’.
3.3 Merge Entity
Merge multiple entities into a single entity with the same property. After selecting entities to merge by
checking corresponding check boxes from the list, select the merge standard entity and press ‘Merge’ button.
(It activates only before Mesh is generated.)
Select all : Select all entities
3.4 Smash
Smash:
Undo the merge function performed to return the merged entities to their initial state. Select ‘Smash’ func-
tion by clicking the right mouse button on top of the merged entity.

3.5 Discontinuity
Display the edge that is disconnected from the adjacent triangle among the edges of triangle that compose
the surface of the entity.
3.6 Entity Properties
1) Through the right mouse button click, display the Quick Menu (Properties->General) and select volume,
surface area, Modulus and weight.
Or select from the ‘Measure’ menu

Volume: Total volume of all entities except for automatically built mold
Surface Area: Total surface area of all entities except for automatically built mold
V/A: Modulus
Weight: Weight
2) The Entity tab of Property Window displays the respective volume, surface area, Modulus and weight of
entities.

4
Measurement
After switching the mouse to Select Mode, selecting the white vertex will display the following measure-
ments on top of the screen.
4.1 A Vertex based Measurement
1) Select one of the followings from the ‘Toolbar’ or the ‘Measure’ menu.
Vertex Coordinate: Coordinate of a selected vertex
Distance between2 Vertices: Distance between the two vertices selected
Center Point of Segment: Center point of segment composed of two vertices selected
3 Vertices Angle: Angle between the three vertices selected
3 Vertices Radius: Radius of the circle composed of three vertices selected
2) Switch the mouse to Select Mode by pressing the spacebar.
3) Clicking a vertex to measure will display the following information (distance and displacement) on the
upper part of the screen:

Mesh Generation
5
A mesh, which is a hexahedron of a certain size, is the smallest unit composing the simulation domain. Mesh
generation requires careful attention and consideration since a mesh has the most effect on the accuracy of
the simulation results. All meshes generated must be reviewed in various ways including the cross-section
observation. Mesh generation also requires much practice since the quality of meshes generated is de-
pendent upon user’s capability.
5.1 Set Entity
Double-clicking an entity or selecting the ‘Mesh -> Set Entity’ menu will display the entity color, name,
property, etc. contained in the system. Select the respective properties of entities from the ‘Type’ combo box.
Name Entity name

Type Select entity property. Selecting the ‘CAST’ type
will also require selecting sub-property
Visible Show/hide
Mode Select rendering property
Color Select color
Transparency Set transparency level

5.2 Set Mold
Casting Only: For a simulation of casting only, areas surrounding the casting are perceived as air. This func-
tion is mainly used for flow simulation
Casting + Mold: For a simulation of both casting and mold
Box: For creating a virtual rectangular mold, enter the wall thickness of the mold for all directions
Shell: For a shell mold during investment casting process, enter the shell wall thickness
Mold Entity: This function is applicable exclusively for a mold built upon importing the geometry from CAD
file or for selecting ‘Mold’ as entity property
Make CAST From the Cavity of Mold: In the case where only mold data exists without cavity data, all areas
except the mold area within the domain (simulation area) are perceived as cast.

Gate Plane
Select the plane on which gate is located among the six planes of simulation area and the wall thickness is
automatically set as ‘0’.
Mold Extent for ‘Casting Only’ Mold Extent for ‘Casting + Mold’
- Black line area is for the gate plane setting
*Note In the case of cyclic casting, at least two entities that are mold properties (upper & lower molds or
fixed & moving molds) are needed, and ‘Mold Entity’ must be selected in the ‘Mold Type and Dimen-
sion’ field.
5.3 Set Domain
Simulation domain is defined by selecting certain areas of the entire domain (mold) through the coordinate
or ration of the outside mold. For symmetrical casting, symmetrical planes can be set for simulation.
Information
Displays the entity & mold domains.
Domain and Symmetry

Coordinate: Coordinates of the boundary interfaces of current
domain
Ratio: Ratios of the current boundary interface to the entire
mold area size
Symm.: Symmetrical planes are selected using the check boxes
of six planes

Displays the size of simulation extent compared to the
domain of the set mold.
Black line area is for the symmetrical plane setting
Default
Change the simulation extent to the initial mold size
5.4 Build Uniform Mesh
Divide the set domain into particular size meshes. Information on optimized mesh is displayed when the
‘Apply’ button or the ‘Enter’ key is pressed after entering values in each field.
Meshing Scheme
Sub-Division Number
The division number of unit mesh in the directions of
each axis. It is required to calculate RealFlow, and the
number ‘3’ or above is recommended.
Total Number of Cell

Select the number of cells in the entire domain. Move
up/down the slide bar on the right or directly enter a
specific number in the field.
Number of Cell Along Axis

Select the number of cells along each axis
Size of Unit Cell

Select the size of a cube cell
Size of Cell
Select the size of cell along x,y,z directions
Domain Size
Display the size of domain
*Note In the case of discontinuous mesh generation for entities with ‘CAST’ property, a warning message is
displayed while highlighting the isolated mesh with yellow outline.

5.5 Build Variable Mesh
In the case of building variable mesh for the purpose of increasing the accuracy of simulation in particular
areas within the domain, applying auto-type of mesh generation algorithm can increase the accuracy by
reducing the number of meshes used in the simulation. At the same time, it can also save calculation time
and reduce memory usage.
1) Blocks Type
User Block:
Block generated through user-defined Start and End points
Auto-Block:
Block generated by clicking the ‘Auto-Block’ button after selecting
block
2) Set Fields
Sub-Division Number:
Unit mesh division number along the directions of each axis.
It is required for the RealFlow calculation and the number ‘3’
or above is recommended.
Axis: Select the axis in the direction to decide mesh size
Blocks
Block Start: Start point of block
Block End: End point of block
Dividing Number: Number of meshes in the block
Set: Set block according to the ‘Block Start’, ‘Block End’ and
‘Dividing Number’ values entered
Remove
Current Block: Delete the current block selected
Auto-block: Delete only auto-generated block
All Block: Delete all blocks
Auto-Block
Smooth Factor: Increase ratio of adjacent cell sizes
Max. Size Ratio: Define the limit of the increasing cell size
Auto-Mesh
Min. Size : Minimum standard size for Auto-Mesh(mm)
Max. Size : Maximum standard size for Auto-Mesh(mm)
Show Grid: Show/hide the block grid

3) Build Block
Build X, Y, Z Axis User Block

1. Select the axis.
2. Press the spacebar to switch the mouse to Select Mode.
3. Select two vertices on the screen to set the start & end point of the block.
4. Pressing the ‘Set’ button or the ‘Enter’ key after selecting the ‘Dividing Number’ will display the newly built
block.
Build Auto-Block
Pressing the ‘Auto-Block’ button after completing the user block setting will automatically build block in areas
where block has not been selected.
Build Mesh
1. Create a user block.
2. Build an auto-block.
3. Repeat the above steps for each axis and press the ‘OK’ button to build mesh.
*A block marked in red line appears as a result of the failure to automatically build block due to the different
division ratios of two blocks located next to the current block. To correct the situation, the following values
must be revised to build mesh once again:
① Select the ‘Dividing Number’
② Change the ‘Smooth Factor’ and the ‘Max. Size Ratio’
③ Change the ‘Dividing Number’ of the blocks at each end
Try building mesh once again after making the above revisions.
Remove Block
Remove Current Block: Press the ‘Remove’ button and select ‘Current Block’
Remove Auto-Block: Press the ‘Remove’ button and select ‘Auto-Block’
Remove All Blocks: Press the ‘Remove’ button and select ‘All Block’
Change Block
Change the respective values of the ‘Start’, ‘End’ and ‘Dividing Number’ fields and press the ‘Set’ button.
*Note
In the case of (more than two isolated areas of) discontinuous mesh generation for entities with ‘CAST’
property, a warning message is displayed while highlighting the isolated mesh with yellow outline.

5.6 Import Mesh
anyMESH is used to import revised mesh information.
Import revised mesh information file (*.mshx, *.msh)
*Note
It is recommended that mesh information is revised at the last step since the revised information will be lost
when mesh is built after importing revised mesh information, which will require reediting.
5.7 Undo Meshing
This function is performed to revise the pre-mesh generation step information such as entity, mold and
domain.
A warning message for losing certain set-

ting conditions upon performing the ‘Undo
Meshing’ function
*Note
Performing the ‘Undo Meshing’ function after having set basic simulation conditions will require resetting of
certain conditions (gate, mold material).

5.8 Review Mesh Information
This function is used to review the detailed information of mesh after building mesh.
*Note
Simulation time can be saved by reviewing the minimum mesh size of each axis once again after the variable
mesh generation to find/remove relatively small and insignificant mesh.

Overview of Simulation Conditions
6
There are four main simulation condition setting items, as shown below.
1) Basic Procedure: Basic setting
- Task Design: Select casting process & simulation - Material Setting: Select material
extent
- Initial and Domain BC: Initial & boundary conditions - Heat Transfer Model: Set heat transfer coefficient
& coating
- Gate Condition: Gate setting (velocity, pressure, - Gravity Force: Set gravity force direction
height, temperature)
2) Optional Modules: Optional setting
- Shrinkage Model: Shrinkage defect prediction - Fluid Flow Model (Turbulence, Surface tension):
model Fluid flow (turbulence, surface tension) model
- Microstructure Model: Microstructure prediction - Segregation Model: Segregation prediction
model model
- Thixo Model: Thixo model - Oxide/Inclusion Model: Oxide/inclusion predic-
tion model
- Cyclic Casting: Set cyclic casting conditions - Vacuum/Air-Vent: Set vacuum/air-vent conditions
- Back Pressure: Set back pressure conditions - Gravity Tilting: Set gravity tilt pour casting condi-
tions
- Large Ingot: Set large ingot conditions - Shot-Sleeve: Set high pressure die casting sleeve
conditions
- Particle Tracing: Set particle tracing conditions - Mold Erosion: Set mold erosion conditions
3) Set Instruments: Various instruments setting
- Sensor: Set sensor - Channel: Set cooling/heating channel conditions

- Pouring Basin: Set pouring basin conditions - Stopper: Set stopper conditions
- Stalk: Set stalk conditions - Filter: Set filter conditions
4) Launching Condition: SOLVER launching condition setting
- Solution Method: Set solution method - End/Output Condition: Solution end & result
output conditions
- Run: Start solution

6.1 Input Data
1) Input Data Type

There are five types of input data, as shown below.
Constant: Constant
Variable(Time): Changing value according to time
Variable(Fill): Changing value according to filling ratio
Variable(Fs): Changing value according to solid fraction ratio
Variable(Temp.): Changing value according to temperature
2) Variable Data Input Method

In the case where the y axis values (velocity, pressure, temperature, etc.) change according to the us-
er-defined x axis values (time, solid fraction ratio, filling ratio, etc.), they can be entered/revised using the
following dialog box. The input values are automatically aligned according to the x axis values and the
changes made are reflected in graph in real-time. Specific values of different points that compose the graph
can be checked through mouse click.
Add: Click button or select ‘Add’ from the list displayed through the right mouse button click
Delete: Click button or select ‘Delete’ from the list displayed through the right mouse button click
Select ‘Delete All’ from the list displayed through the right mouse button click to delete all input values
Edit: Click button or select ‘Edit’ from the list displayed through the right mouse button click

Basic Procedures
7
7.1 Task Design
1) Target Process
Select a casting process from the below four groups for simulation.
Group 1(Non-Metal Mold) Group 2(Metal-Mold)
Sand Casting Metal-Mold Casting

Investment Casting Gravity Tilt Pour Casting
Group 3(Pressurized) Group 4(Special)
High Pressure Die Casting Centrifugal Casting

Low Pressure Die Casting Gravity Tilt Pour Casting
Vacuum Die Casting Electro Slug Melting Process
Squeeze Casting
Thixo-Forming Process

2) Analysis Type
Mold Filling (No Heat): For filling simulation only

Heat/Solidification: For heat/solidification simulation only
Mold Filling and Heat “During Filling”: For mold filling & heat during filling simulation
Mold Filling and Heat/Solidification “During and After Filling”: For mold filling & heat/solidification during &
after filling simulation
7.2 Material Setting
Select entity materials from the database.

1) Select/Change Entity Material
 Select entity from the list (Multiple selections are possible through Ctrl or Shift + left mouse button click).
 Press the ‘Database’ button or double-click the selected entity/entities.
 Select alloy system, name spec. from the dialog box.
 Double-click the material selected or press the ‘OK’ button to set entity material.
 Air properties are set automatically.
2) Change Material Properties

 The Material Information list displays 12 different properties.
 Double-clicking the properties will display the following ‘View/Edit’ window.
 Double-click the data to revise and press the ‘OK’ button to complete the process.
(The ‘OK’ button is activated only when all entity materials have been set).
3) Use User Defined Material Information

 Open the ‘Preferences’ window from the ‘File-Preference’ menu.
 Click button from the ‘Database’ menu and select the *.adb or *.mdb file created in anyDBASE.
 Select the ‘User Database’ button from the list.

4) Calculate Thermal Property of Alloy using MPC(Material Property Calculator)
Thermal property required for simulation can be calculated by entering the alloy composition information.
As shown below, select combo box located next to the ‘Database’ button, and click
button.
Material: Select alloy

Start: Calculation start temperature
End: Calculation end temperature
Step: Calculation temperature gap
Fraction Limit: Solid or liquid fraction
Cast Iron Option

Pearlitic: Apply matrix structure as Pearlitic
Austenitic of Ferritic: Apply matrix structure as Austenitic of Ferritic
Graphite Type: Select graphite type (Spheroidal, Compacted, Lamellar)
C Equivalent: Carbon equivalent
Composition: Enter chemical composition
Load/Save material Condition: Save/load alloy composition information
Load Result…: Load calculated property information
Start Calc: Start calculation

Calculated property value can be checked from the list window, and
the result can be applied to the user database.
7.3 Initial and Domain Boundary Condition
1) Initial Conditions
Select the initial thermal conditions of each entity.
In the case of a CAST property entity, it is presumed to be filled with air since the inside is an empty space
before the filling. On the other hand, enter the melt temperature for a simulation of heat/solidification only
(‘Heat/Solidification’ is selected for Analysis Type) since the inside is filled with constant temperature melt. In
the case of preheating the mold, enter the preheating temperature.
The default temperature of cavity for initial temperature is 25℃ before melt pouring.
If user wants to apply the temperature distribution result from previous thermal analysis as initial temperature,
it can be used as the initial temperature distribution for a new simulation.
Activate the initial distribution function and set the acrx file path for the point that will be applied.

2) Domain Boundary Condition
Set the thermal conditions of each boundary (±x, ±y, ±z).
Normal Thermal transfer including convection

and conduction
Adiabatic Adiabatic plane
Constant Temp. Constant temperature
Variable Temp.(Time) Changing temperature according to
time
Constant Flux Constant heat flux
Variable Flux (Time) Changing heat flux according to time
7.4 Heat Transfer Model
This function automatically locates and displays the interfaces between entities.
Set the respective heat transfer coefficient of each interface displayed on the list. Multiple selections/settings
are possible.
1) Set Heat Transfer Coefficient

Heat transfer coefficient of interface can be imported from the database or determined by user.

*change1 – contents
Heat Transfer Coefficient

- Database: Automatically sets the HTC according to the two adjacent materials. Select casting process such
as ‘Gravity’, ‘Low’ or ‘High Pressure’
- User defined: Defined by user
- Constant: Enter constant value
- Variable(Time): Enter changing variable according to time
- Variable(Fs): Enter changing variable according to filling rate
- Variable(Temp.): Enter changing variable according to temperature
- Reset To Default : set Default HTC value
*Note
Default HTC Values according to Casting Process
1. Group 1 (Non-Metal Mold)

1.1. Sand Casting
Entity 1 Entity 2 HTC
1 Air All 0.001
2 Cast Mold/Core 0.1
3 Cast Attached 0.2
4 Mold Inserted 0.6
5 Mold Mold 0.6
6 Exothermic Cast 0.1
7 Exothermic Mold 0.001
1.2. Investment Casting

1 Air All 0.001
3 Cast Attached 0.2
4 Mold Inserted 0.6
5 Mold Mold 0.6

2. Group 2 (Metal Mold)

2.1. Metal Mold Casting
1 Air All 0.001
3 Cast Attached 0.2
4 Mold Inserted 0.6
5 Mold Mold 0.6
2.2. Gravity Tilt Pour Casting

1 Air All 0.001
2 Cast Cast 0.05
3 Cast Inserted 0.05
4 Cast Mold 0.05
5 Inserted Cast 0.05
6 Inserted Mold 0.6
7 Mold Mold 0.6
3. Group 3 (Pressurized)
3.1. All Process
1 Air All 0.001
2 Cast Cast 0.05
3 Cast Inserted 0.05
4 Cast Mold 0.05
5 Inserted Cast 0.05
6 Inserted Mold 0.6
7 Mold Mold 0.6

4. Group 4 (Special)
4.1. Centrifugal Casting
1 Air All 0.001
3 Mold Inserted 0.6
5 Mold Mold 0.6
4.2. Electro Slug Melting Casting

1 Air All 0.001
3 Mold Inserted 0.6
4 Mold Mold 0.6
2) Set Coating Layer

Select the heat transfer& coating layer thickness of the materials that will be coated for the selected inter-
face(s).
Double-click interface(s) from the list or press the ‘Database’ button and select materials from the ‘Coating’
group.
Coating Material: Name of coating agent

Thermal Conductivity: Thermal conductivity of coating agent
Coating Thickness: Thickness of coating agent

7.5 Gate Condition
Gate conditions can be mainly divided into two steps – during filling and after filling. Gate setting plane can
be added/deleted through mouse click. This function support multiple gate & direct-pouring settings.
Select/Deselect Gate
1. Click the ‘Gate Condition’ button while pressing the spacebar.
2. Areas that can be selected are displayed in brown color.
3. Press the spacebar to switch to Select Mode.
4. Areas displayed in brown color will change to yellow color and be added to the list when they are selected
through mouse click.
(Areas that can be selected as gate are displayed only in Mesh Mode and not in Geometry Mode.)
5. Gate that has been selected (displayed in yellow) can be deselected by selecting it once again.
Before gate setting During ‘Gate Condition’ setting After gate setting

1) Back-flow Control
In the case of low pressure casting where the pressure created towards gravity direction from the mass of
melt being filled through stalk is higher than the pouring pressure, the phenomenon of melt surface flowing
down towards the bottom of stalk can be simulated.
(This function can simulate that the volume of filled molten metal in the cavity is reduced.)
2) Gate Condition Settings

Select the ‘Gate Condition’ menu to open the gate condition settings window and the areas that can be se-
lected as gate are displayed in brown color.
Press the spacebar to switch to Select Mode.
Select an area displayed in brown through mouse click and it will be added to the list.
Selecting the current gate (displayed in yellow) once again will deselect the current gate.
3) General
Name: Set gate name. The default value is “Gate_number”.
Flow Direction: Display the filling/flow direction
4) During Filling (before melt filling is completed)

Thermal Condition: Set the thermal conditions of melt
Flow Condition: Set the flow conditions (select velocity, pressure or height)
5) After Filling (after melt filling is completed)

Thermal Condition: Set the thermal condition of the gate surface exposed to the outside (after filling is
complete)
- Normal: Heat transfer conditions including convection, conduction and radiation
- Adiabatic: Adiabatic conditions
- Temperature: Constant temperature
- Heat Flux: Constant heat flux
6) Advanced Option
Direct Pouring: Assign surface area through which pouring melt from cup passes
Estimated Filling Time: Display the estimated filling time at constant velocity condition

*Gravity Casting using Pouring Cup
In the case of gravity casting using pouring cup, melt is filled through free fall. In the case of gravity casting
using pouring cup, a certain area that is considered as the pouring path can be set. Enter the center coor-
dinate & radius of pouring area in the below window, and the pouring path is displayed in a red circle.
Before setting After setting (red circle)
Center Point: Enter the center point of pouring path (actual pouring point)
Radius: Enter the radius of pouring path (actual pouring size)
7.6 Gravity Force
Set the magnitude and direction of gravity force.
Enable: Enable gravity force setting

Direction: Select the direction of gravity force
±X, ±Y, ±X, other(when not parallel to axis)
Magnitude: Enter the magnitude of gravity direction

Optional Module
8
8.1 Shrinkage Model
This model is used for shrinkage cavity prediction.
Enable: Enable shrinkage model function

Material: Material setting
Solidification Shrinkage
- Database: Enter the value of material property da-
tabase
- User define: Enter user database value
Gravity Shrinkage : Enable gravity shrinkage

Feedability : feeding rate (when the product is solidi-
fied)
- Database: Enter the value of material property da-
tabase
- User define: Enter user database value
(Value range : 0 ~ 1)
Solid Fraction : Setting criterion of Solid Fraction ratio

for output (Value range : 0.1 ~ 0.9)
*Note
By selecting User define in Solidification Shrinkage / Feedability, User can change the value
e.g. Input 5 in Solidification Shrinkage -> When the product is solidified, shrinkage rate of volume and surface
is 5%.
e.g. Input 0.7 in Feedability -> When the product is being solidified, remainder of melt is fed to shrinkage area
until reaching Solid Fraction ratio 70% in solid/liquid coexistence area.
Criteria for generating Solid Fraction shell : when user enter the lower value, generating Solid Fraction shell is
promoted

8.2 Fluid Flow Model
1) Surface Tension
In the surface tension model, surface tension coefficient and wall adhesion angle for analyzing wall adhesion
force are defined.
Enable: Enable surface tension model

Model: Standard CSF Model
Surface Tension: Enter surface tension coefficient
Category: Enter database value or user-defined value
- Type: Enter constant or variable temperature
- Value: Enter surface tension value
- Wall Adhesion Model: Enable wall adhesion force analysis &
enter contact angle.
※Surface tension can be expressed as follows:
  C  K
C
: Coefficient of Surface Tension
K: Curvature
The wall adhesion effect can be incorporated in the simulation through the setting of wall adhesion angle at
which melt contacts the wall. The wall adhesion angle is the angle indicated below.
Definition of Wall Adhesion Angle

2) Turbulence
Set turbulence model for analyzing turbulence flow
Enable: Enable turbulence model

Model: Select turbulence model
Standard k-ε model
RNG k-ε model
Wilcox k-ε model
※There are various types of formulas used for turbulence model. The standard k-ε model, which is the rep-
resentative turbulence model, consists of two differential equations and one equation on turbulent viscosity.
k k    t  k 
 uj       P 
t xj xj   k   x j  k
    t     2
uj       C 1 Pk  C 2
t x j x j     x j  k k
The constant values are as follow:

Standard k-ε RNG k-ε Wilcox k-ε
0.09 0.085 0.09
1.44 1.42 0.56
1.92 1.68 0.075
1.00 0.7179 2.00
1.30 0.7179 2.00

8.3 Microstructure Model
For microstructure prediction model, deterministic model and parametric model are provided.
1) Deterministic Model
This model is for calculating the grain size or the nodularity of spheroidal graphite.
Enable: Enable deterministic model
Alloy System: Select alloy system

- Al-Cu Alloy: 4.5wt%Cu standard
- Al-Si Alloy: 7wt%Si standard
- Ductile Cast Iron: Spheroidal graphite iron
- Magnesium Alloy: AZ901D standard
- User defined: For entering new values other than those provided above

Nucleation Kinetics: Enter data on nucleation kinetics
: Entering and revising data on nucleation kinetics is enabled only through user setting.
: Standard Equation– nucleation distribution curve according to under cooling
① Power: Exponential function

Parameter K: Nucleation coefficient
Parameter n: Nucleation exponent
② Gaussian: Gaussian distribution curve

Maximum Nuclei Density: Maximum nuclei density
Mean Nucleation Under Cooling: Mean nucleation under cooling
Standard Deviation: Standard deviation of nucleation under cooling
③ Hyperbolic: It is based on cosine hyperbolic function and the data setting fields are the same as that of the
Gaussian distribution curve.
Growth Kinetics: Enter data on growth kinetics

: Enter data on crystal growth kinetics
: Standard Equation–crystal growth rate equation according to under cooling
① Polynomial: Thevoz’s cubic equation

Parameter (a): quadratic coefficient
Parameter (b): cubic coefficient
② Power: Exponential function

Parameter K: Nucleation coefficient
Parameter n: Nucleation exponent
This model is based on nucleation and crystal growth kinetics. Accordingly, data input and selection should
be done carefully since valid data on the two types of kinetics will lead to reliable result output.

2) Parametric Model
This model is used to obtain information on various types of microstructure, and solute diffusivity, heat
diffusivity and capillary characteristic length are calculated to be used as the basic parameters of structural
prediction.
Enable: Enable parametric model
Alloy System: Select alloy system

Al-Cu Alloy: 4.5wt%Cu standard
Al-Si Alloy: 7wt%Si standard
Ductile Cast Iron: Spheroidal graphite iron
Magnesium Alloy: AZ901D standard
User defined: For entering new values other than those provided above
Gibbs-Thomson Coefficient: Under cooling coefficient from the capillary tube effect
Initial Solute Concentration: Initial solute concentration
Solute Diffusivity in Liquid: Coefficient of solute diffusivity in liquid
Liquid Slope: Liquid slope
Partition Coefficient: Partition coefficient
Inter-atomic Distance: Inter-atomic distance

8.4 Segregation Model
Segregation conditions can be set as shown below:
Solute Setting
Add: Add new species
Properties: Display the properties of
selected species
Delete: Delete selected species
Delete All: Delete all species
Properties Setting
Click the ‘Properties’ button or double-click species from the list.
Species: Enter species name

Initial Concentration (Co): Initial concentration of solute
Partition Coefficient (k): Partition coefficient
Diffusivity in Solid (Ds): Coefficient of species diffusivity in solid
Diffusivity in Liquid (Dl): Coefficient of species diffusivity in liquid
Solutal Expansion Coeff.: Coefficient of species expansion

8.5 Thixo Model
This model is for setting viscosity according to Non-Newtonian flow.
Enable: Enable thixo model

Material: Indicate the material of entity set as cast
Model: Select viscosity model
Effective Viscosity Model
Bingham Model
Carreau Model
Power Law Model
Ellis Model
Settings: Input value of the selected viscosity model

The followings are five types of viscosity models excluding the Newtonian flow.
Effective Viscosity Curve Model

Functional modeling of qualitative changes according to solid
fraction ratio.
   tan 1 C2  fs  C3     0 : viscosity value

  0 1  C1 1   0.5   
      C1 , C2 , C3 : model consonant
Bingham Viscosity Model
  0   y / D
,
 0 : viscosity value
 u u j   y : yield stress of material
D   ij ij / 2  ij   i 
 xi

ui 
, (Shear rate)
Carreau Viscosity Model

  0   1    D 2  n1 / 2
  D   ij ij / 2   : viscosity value
,
when shear rate reaches infinity
n,  :model constant
Powerlaw Viscosity Model
  0  D n1 , D   ij ij / 2
n : model consonant
Ellis Viscosity Model

  0 / 1   /  0   1
, D   ij ij / 2 0 :  for   0 / 2
n,  :model constant

8.6 Oxide/Inclusion Model
This model is for predicting the oxide distribution within cast by setting the amount of oxide generated.
Enable: Enable oxide/inclusion model

Amount: Set the amount of oxide generated
Critical Value: The default value is set as ‘0.001’
 Oxide/inclusion model setting values are as follow:
Temperature Dimensionless
Solidus Temperature 0
Pouring Temperature 1

8.7 Cyclic Casting
Cyclic casting conditions can be set in the window shown below. Click the ‘Cycle’ and ‘Event’ and Control By
Sensor tabs to set various fields.
8.7.1 Cycle
Set the cycle of simulation
Add: Click the ‘Add’ button (The default setting is for ‘Heat/Solidification’ analysis type)
Delete: Click the ‘Delete’ button (The ‘Delete All’ button will delete all cycles)
Edit: Select an item to edit by double-clicking the item or pressing the ‘Properties’ button
Heat/Solidification : Enable solidification analysis

Fluid Flow : Enable fluid flow analysis
Shortened Output : Enable shortened output file of cycle
*Note
To save calculation time, only the ‘Heat/Solidification’ analysis is performed in all cycles except for the mid and
last cycle in which both the ‘Heat/Solidification’ and the ‘Fluid Flow’ analyses are performed. Click the ‘Prop-
erties’ button to select analysis type.

8.7.2 Event
Set the time for each event. As in the case of ‘Cycle’, the ‘Add’ or ‘Delete’ buttons is used to add/delete events.
As events are added/deleted/edited, their respective cycles are automatically calculated and displayed in the
‘Cycle Time’ field located at the bottom of the window. Basic events can be added by clicking the ‘Add’ button
(Die-Open, Disassemble, Remove, Spraying, Die-Close and Lead Time).
1) Disassemble
Selected entity disassembles once the mold opens and reassembles when the next cycle begins.
To set the Disassemble event:

① ATTACHED/INSERTED type entities are displayed in the list.
② Input event occurrence time.
③ Select entity that will be disassembled in this event.
*Note
It is presumed that the entity that will be disassembled in the Dis-
assemble event is exposed to air, which will also allow heat transfer.
Accordingly, the temperature distribution analyzed by anySOLVER
will be used as the entity temperature of the following cycle. (e.g.,
reusable core)

change1 – picture (Die-Open), delete (Reset Temperature)
2) Remove
Selected entity is removed after the die-open and other entities except for CAST type entity are reassembled
at the start of the next cycle.
To set the Remove event:
① CAST/ATTACHED/INSERTED type entities are displayed.
② Input event occurrence time.
③ Select entity that will be disassembled in this event.
*Note
Entity that is removed in the Disassemble event is not reused in the next cycle. Accordingly, the user-defined
initial temperature is used as its initial temperature. ALL CAST type entities should be selected as entities that
will be removed in the Remove event.
3) Die-Open
To set the Die-Open event:
① Input die-open time.
② Select moving-die. Unselected entities are automatically set as
fixed-die.
*Note
Cyclic casting requires at least one moving/fixed die.

change1 – picture (Spraying)
4) Spraying
This function is set for parting die coating by spraying& cooling spraying after the open-die.
To set the Spraying event:
① Input spraying start time & spraying time.
② Input the spraying media (refrigerant) temperature & volume flux.
Browse Surface : Setting the sprayed entity

(Surface Browse Dialog window)
Spraying Condition
Media Model : Setting temperature, volume flux
HTC Model : Setting temperature, HTC
*Note
Spraying or blowing affects/cools the following interfaces:
- Interface between moving-die and fixed-die
- Interface between entities that are removed during the Remove /
Disassemble events and the mold
Primary Entity : Sprayed entity

Sencondary Entity : Entity contacting with Primary Entity
(In the case of selecting Primary Entity, Secondary Entity is activated.)
*Note
- In the case of selecting all Secondary Entities, it is sprayed onto whole Primary Entity surface.
- In the case of selecting arbitrary Secondary Entity, it is sprayed onto contacting with Primary Entity surface

5) Die-Close
This function is used to set the die-close time after the cooling.
To set the Die-Close event:
① Input die-close time.
Reset Temperature : Reset the initial temperature of entity that is removed with CAST and is inserted before
Die-Close.
*Note
All entities except for CAST type entity are reassembled at the moment when the die closes.
6) Lead Time
It refers to waiting time between the end of a cycle and
the start of the next cycle (before melt injection).
To set the Lead-Time event:

① Input lead time.

8.7.3 Control By Sensor
This function is used to set the start time of each cycle based on previously set a sensor temperature
Temperature : Set the standard temperature of a sensor

Setting
BELOW_THAN : Start next cycle below than set temperature
ABOVE_THAN : Start next cycle above than set temperature

The following is a diagram of a common cyclic casting process.
Time Graph Geometry status Event
Mold Filling &
Filling & Heat/Solidification Process
Heat/Solidification Process
Core Removal
Start Die Opening
Ejection
Start Die Spraying
Spraying Time
Die Closed
Lead Time
Waiting for the Next Cycle

8.8 Back Pressure
Back pressure is calculated by incorporating the resistance placed on melt, while it is being filled, by the air
inside the mold in the free surface of melt.
Enable: Enable back pressure model

Initial Pressure: Input initial pressure
Parting-Line: Enable simulation that includes parting plane of
metal mold
- Average Gap Thickness: Gap thickness of metal mold parting
planes
8.9 Vacuum/Air-Vent
This function is used to set vacuum & air-vent conditions.
Select/Delete Vent
① Open the Vacuum/Air-Vent window.
② Selectable areas are displayed in brown color.
③ Press the spacebar to switch to Select Mode.
④ Click on the area displayed in brown(Selected area is added to the list).
⑤ Selecting the current air-vent (yellow) once again will delete it.
No: Number of outlets

Vent: Name of each outlet (Default: outlet_#)
Status: Status of outlet
Continuous Flow-Out: Assume that outlet is continuously con-

nected.
Exposed to Environment: Exposed to air
User-Defined Pressure: Input user-defined pressure based on air
pressure (1013250dyne/cm2)
- Constant : Enter constant value
- Time : Enter changing pressure value according to time
- Filling Rate: Enter changing pressure value according to filling rate
- Displacement : Enter changing pressure value according to tem-
perature
*Note
If back pressure did not be set, user could not set User-Defined Pressure.

8.10 Gravity Tilting
This function is for setting gravity tilting conditions.
Enable: Enable gravity tilting

Tilting Axis: Set tilting axis
Origin: Origin of tilting axis
Vector: Vector of tilting axis
±1,0,0 for rotation around ±x axis
0,±1,0 for rotation around ±y axis
0,0,±1 for rotation around ±z axis
Tilting Angle: Set tilting angle
Start, End: Tilting start & end degrees
Tilting Speed: Set tilting speed
Time vs Angle
Set Tilting Axis Vector Value

1. To determine the vector of tilting axis, spread out the thumb
and fold the remaining fingers.
2. Axis parallel to the thumb is the vector of tilting axis.
3. Vector value is +1 when the tilting axis and the thumb are
facing the same direction and the value is -1 for the opposite
direction.
In the case of the image shown on the left, the direction is
(-1,0,0).

8.11 Large Casting
1) Fast Flow
When steadily pouring molten metal at random step, user can save the simulation time by increasing the
Time Step at fluid simulation.
Enable: Enable Fast Flow

Increasing Rate of Filling:
Filling amount of a given step (Default: 0.01%)
On/Off Control: Section in which the Fast Flow function is
applied
2) Additional pouring
Click ‘Add’ button to display

the ‘Additional Pouring Con-
dition’ window
.
Time: Additional pouring start time (sec)
Solute concentration is changed:

Check this field for changing solute concentration during additional pouring. In inactive status, use to C0
concentration (initial concentration).
Solute list window: Double-click C1 to input solute concentration. C0 cannot be changed since it is reference
value. It activates only when segregation model has been activated. As for setting the pouring condition in
the case of additional pouring, set the additional pouring time (t2), as stated above, and set the gate velocity
and temperature conditions as follows:

Velocity Condition
According to the additional pouring time (t2), velocity of t1~t2 section (no pouring) is set as 0. To help in
determining the gate open/close status, set as t1+tc, t2-tc (tc=0.1sec).
Velocity
v2
v1 t1+tc t2-tc
0 t1 t2 Time
Temperature Condition
Set temperature condition as follows to allow the melt temperature to be T2 at the additional pouring time
(t2) after the initial pouring end time (t1):
Please note that setting 0 in t1~t2 section, as in the case of the velocity condition, could lead to a situation
where pouring does not occur as the melt temperature during additional pouring (t2) becomes 0 degrees or
pouring occurs after the completion of shrinkage.
Temperature Temperature
T2 T2
T1 T1
0 t1 t2 Time 0 t1 t2 Time
CAST Type Setting

To ensure effective simulation, physically insignificant areas or areas difficult to simulate should be removed
since flow and segregation are simultaneously calculated during the solidification calculation stage after the
filling. This is set automatically in Solver and user needs to set the pouring method – top gate method or
bottom gate method.

Top Gate Method
As shown in Figure (a), gate is no longer needed
after filling and the VOF value becomes 0 after
filling by setting INGATE. Namely, it becomes ex-
cluded from domain.
Bottom Gate Method

As shown in Figure (b), the RUNNER section causes
instability in the velocity calculation. Accordingly,
the RUNNER setting will disable the calculation of
the flow in of the corresponding cell after filling
(a) Top gate (b) Bottom gate
and while enabling the calculation of heat transfer.
Namely, it only calculates solidification not flow.
8.12 Exothermic Powder
1) Exothermic Powder
This function is a way to simulate the exothermic agents Installation to

delay solidification of the melt surface on lastly poured molten metal.
Users can input the start time of combustion, and the melt surface is
regarded as in contact with air prior to the start of combustion for
heat transfer.
Edit : Edit selected entity
Enable: Enable exothermic

Start Time of Combustion: Input combustion start time
Combustion Type
Flux : Input Time and Heat Flux
Temperature : Input Time and Temperature
Adiabatic
8.13 Shot-Sleeve
Set the operational conditions of die casting equipment to automatically calculate and set the gate velocity &
time of high/low velocity stroke. In general, the entire sleeve is not included in the calculation but some parts
of biscuit or runner are included to save memory & calculation time and the velocity condition is set auto-
matically as the set operational condition.
8.12.1 Sleeve
Dimension: Sleeve size

- Length(Ls): Sleeve length
- Inner Diameter(Ds): Sleeve diameter
Biscuit: Biscuit setting

- Length(Lb): Biscuit length
'Biscuit' is included in the domain:

Check this field when biscuit is included in the domain
8.12.2 Melt-Charging
Alloy: Material name

Amount of Melt(Wcast): Weight & volume of melt
- % of Sleeve: Percentage of melt filling inside the sleeve
(based on Sleeve tab)
Mesh-Based Ratio : Percentage of melt filling inside the
sleeve (based on Plunger tab)
Pouring Temperature: Pouring temperature
The pouring temperature of the gate condition is set au-

tomatically.

8.12.3 Shot
Low Speed: Low speed section velocity

High Speed: High speed section velocity
Low Speed Length: Low speed section length
High Speed Length: High speed section length
Transition Factor: Transition duration
Multi-Step Injection : Enable to be set as multi step speed (Setting

button)
Setting... : Set shot speed according to Stroke position.
Reference...: Optimization of high speed injection (The recommended injection speed of cast can be calcu-
lated.)
Clicking ‘Reference...’ will display the following window:
Product: Product condition

Weight: Product weight setting
Average Thickness: Product average thickness setting
In-Gate Area: Total area of In-Gate
Optimized Data: Optimization speed
In-Gate Speed: Optimized high speed according to product condition
High Speed: Sleeve speed according to the In-Gate speed

*Note
- Velocity calculation according to Ingate area

𝑽
a=
𝝂∙𝒕
a = Ingate area
ν = Melt Velocity at Ingate
t = Filling time (sec)
Product Weight
V= = Product volume (including overflow volume)
Specific Gravity
- Specific Gravity
Al : 2.65
Zn : 6.6
Mg : 1.8
Bronze : 8.4
- Ideal Ingate Velocity according to material

Al
Product Weight(g) Ingate Velocity (m/s)
0~500 30
500~1000 40
1000~2500 50
2500~ 60
Zn : 20 ~ 40m/sec
Mg : 40 ~ 40m/sec
Bronze : 30 ~ 40m/sec

- Filling time according to Ingate Thickness
Al
Al Product Weight(g) Thickness(mm) Filling time(sec)
0~500 2.0~3.0 0.04
500~1000 3.0~3.5 0.06
1000~2500 3.5~4.0 0.08
2500~ 4.0 0.10
Zn
Zn Thickness(mm) Filling time(sec)
1.0 0.015
2.0 0.02
3.0 0.05
3.5 0. 7
Mg
Mg Thickness(mm) Filling time(sec)
2.0 0.035
3.2 0.055
3.5 0.07

Optimizing...: Optimization of pouring speed transition section
The length of optimized high/low speed sections can be set by determining the volume of high/low speed
section filling, as well as based on the work conditions set above.
Clicking ‘Optimizing...’ will display the following window:
1. Select entity for low speed section filling.

(Double-click ‘Ratio(%)’ to make any necessary changes.)
2. Pressing the ‘Apply’ button will automatically calculate low
speed filling volume.
3. Pressing the ‘OK’ button will automatically set the length of
high/low speed sections.
Setting... : Set shot speed according to Stroke position. Clicking ‘Setting...’ will display the following window:
Add : Click button
Delete : Click button
Edit : Click button

8.12.4 Plunger
Plunger: Select ATTACHED type entity for plunger tip
Moving Direction: Moving direction of plunger tip
Initial State of the Sleeve Cavity: Initial state of melt

- Filled with Certain Amount of Melt:
Pouring amount of melt is already filled
- Empty (Melt is supplied from a pouring-hole):
Pouring amount of melt is filled through gate
(This function requires gate entity and gate condition setting.)
Holding Time: Holding time before moving plunger tip.

8.14 Centrifugal Casting
In centrifugal casting, the molten metal is poured to mold that is rotated on an axis. There are two types. One
is Horizontal type, the other is Vertical type.
Enable : Enable centrifugal casting

Rotation Axis
- Axis Origin : Coordinate of rotation axis
- Axis Vector : Rotation axis setting
Rotation Speed
- Constant : Input rotation speed
- Variable(Angle) : Input rotation speed according to angle
- Variable(Time) : Input rotation speed according to time
- Variable(Fill) : Input rotation speed according to filling rate
Rotating Entity : Select rotating entity (Mold Entity)
Gate On Rotation Axis : Check when the gate exists on rota-

tion axis.
Center : Gate center setting
Radius : Gate radius setting
*Note
- In the case of setting center and radius, a yellow arrow and
circle are made on model. (After setting Gravity Force)
- In Horizontal type, user should set Flow Direction at Gate
Condition menu.
- Horizontal type cannot be set to Center Gate.

8.15 Particle Tracing
Particles are built according to certain conditions at gate and the melt flow is visualized by tracing its moving
path.
Enable : Enable Particle Tracing

Particle Source Number : Set generating distribu-
tion of particle at gate (Area)
e.g. input 10 -> Create the particle by dividing the
Gate cross-section into 10X10
Total Generation Step : Set the Particle generation
interval in range set by the On/Off Control
On/Off Control
-By Time : Set the Particle generation interval
according to Time
-By Filling Rate : Set the Particle generation interval
according to Filling Rate
-Write Skip Number : Set the Particle moving in-
terval in Iteration when solver analyzes the project
*Note
When the value of Write Skip Number is small, the result of Particle moving is detailed. However the analysis
time increases.
8.16 Mold Erosion
This function is to predict the area of mold erosion by predicting the speed & incidence angle of melt.
Enable: Enable mold erosion

8.17 Flow Tracking
This visualization function provides a clear overview of melt flowing in from gate, Ingate, etc.
Enable: Enable flow tracing

Ingate interface auto-recognition priority order:
1. Cavity-Ingate contact surface
2. Cavity-Runner contact surface
3. Multi-Gate
8.18 Cast Iron
This function predicts the phase fraction & mechanical characteristics of cast iron by analyzing its composi-
tion.
Analysis Factors:
- Alloy element
- Melt treatment
Enable: Enable cast iron module

Composition: Input cast iron composition
C Equivalent: Carbon equivalent (calculated automatically)

- Cast iron module is applicable only to cast iron material and its calculations are performed according to
below formulas:
1) Cast Iron Classification according to Mg Content

Ductile Cast Iron (Globular type): Mg > 0.03 wt%
Gray Cast Iron (Fake type) : Mg ≤ 0.005 wt%
2) Transformation Temperature
Teutectic,stable = 1154 + 4 ∗ wt%Si − 2 ∗ wt%Mn
Teutectoid = 740 + 15 ∗ wt%Si − 3.5 ∗ wt%Mn
*Note
The Process, Formula, Transformation and Temperature are set according to Si, Mg Content.
8.19 Core Gas
This function predicts generated core gas location.
Enable : Enable Core Gas

Core Entity : Select Core entity
Porosity : Set Porosity
Binder Weight : Set Binder Weight

8.20 Gas Entrapment
By using this function, user can predict gas location and volume that is generated when molten metal is in-
jected in cavity.
Enable : Enable Gas Entrapment

Coefficient C0 : Enter Coefficient of equation as below (C0)
Critical pressure : Enter initial gas pressure (Pc)
Tsurface : Temperature of molten metal at the free surface

R : Gas amount(g/cc)
*Note
Critical Pressure value is set according to slope between Gas Pressure(Pgas) and Gas Volume.

9
Set Instruments
9.1 Sensor
Sensors are installed to check the velocity, pressure, temperature and other information at specific locations
within domain. Select the ‘Simulation - Set Instruments – Sensor’ menu to activate cross-section plane and
display the sensor window.
1) Adding Sensor through Mouse

① Move the activated cross-section to a desired position.
② Press the spacebar to switch to Select Mode.
③ Click the desired position to add to the list.
④ Sensor name, entity & coordinate can be checked from the list or the below figure:

2) Adding Sensor through Coordinate Input
Click ‘Add’ button to input the new sensor name (default: Sensor_#) and coordinate.
Possible range of coordinate is displayed, as shown below:
3) Changing Sensor Position

Press 'Properties' button to change the name & position of current sensor in the window shown below.
Possible coordinate range is displayed, as shown below:
4) Deleting Current Sensor

Press 'Delete' button to delete the current sensor.

9.2 Channel
The following window is for setting the cooling channel. CHANNEL type entities are displayed in the list.
To set channel:
① Check the first checkbox field to turn on/off the channel.
② Select channel model (Constant HTC Model, Constant Flux Model).
③ Set the specifics of each channel.
④ Turning on the ‘Clone CHANNEL conditions for the cyclic casting’ function will automatically adjust the
input value during cyclic casting setting.
*Note
Turning off channel will be regarded by the program as the channel filled with air. The heat transfer models
of channel are mainly divided into Constant HTC and Constant Flux models.
Constant HTC Model

This model is used to analyze heat transfer by calculating h, heat transfer coefficient, between channel and
adjacent entity upon using the correlation equation on h according to inflow/outflow temperature, inflow
flux, cross-sectional shape of channel and length. This model has a strong point of changing inflow/outflow
amount in the channel direction according to changes in temperature of entity adjacent to the channel. At
the same time, it also has a weak point of lack of generality that results from using experimental correlation
equation.
Constant Flux Model

This model is used to analyze the heat transfer condition of meshes that compose channel by calculating the
channel inflow/outflow heat flux based on the inflow/outflow temperature of the channel. This model can
be commonly applied regardless of cross-section or inflow/outflow conditions since it does not use experi-
mental correlation equation, unlike HTC based model. However, it also has a weak point in the sense that the
heat flux between channel and adjacent entities is calculated in a constant way.

1) Setting Channel Conditions
① Double-click or select a desired item from the list and click ‘Properties’ button to display the below win-
dow.
② Select media (refrigerant) flow control method.
③ Set specific control methods.
*Note
Length (volume/average cross-sectional area) is used for channel analysis. If ‘0’ is displayed for the ‘Average
Cross-sectional Area’ value, length of chancel cannot be calculated automatically since it means that there is
no channel surface exposed to the boundary interface of entire entity area. In such cases, the ‘Average
Cross-sectional Area’ value should be defined by user.
1. Setting Channel Control Conditions by Time

① Double-click a desired channel from the list and click ‘Time/Flux setting...’ button or click ‘Setting’ button.
② Click ‘Add’ button to add conditions. Multiple control conditions can be inputted.
③ Click ‘Delete’ button to delete conditions.
④ Click ‘Properties’ button or double-click condition items to make any necessary revisions.

Time Control
Flow-On Time: Cooling/heating start time
Flow-Off Time: Cooling/heating end time
Cooling/Heating Media
Settings :Select cooling/heating media
(Air, Oil, Water, User-Define Constant HTC, Variable HTC).
Media Flow Condition

Volume Flux: Volume flux of media (refrigerant)
Inlet/Outlet Temperature: Media (refrigerant) temperature at inlet/outlet
*Note
If user selects a type to Variable HTC, Channel Direction should be input.

2. Setting Channel Control Condition by Sensor Temperature
① Select reference sensor.
② Input control condition.
Sensor Condition
Working Temperature: Valve opening sensor temperature
Working Range: working temperature range
Cooling/Heating Media
Settings :Select cooling/heating media
(Air, Oil, Water, User-Define Constant HTC, Variable HTC).
Media Flow Condition

Volume Flux: Volume flux of media (refrigerant)
Inlet/Outlet Temperature: Media (refrigerant) temperature at inlet/outlet

*Note
Cooling media (refrigerant) will start to flow as the valve opens when the temperature of the reference
sensor reaches working temperature, and the valve closes when the temperature of the reference sensor falls
below the working range. For example, the setting ‘working temperature = 300℃, working range = 30℃’ will
open the valve to start the cooling process when the temperature of the reference sensor reaches 300℃ and
the valve will close when the temperature falls below 270℃.
2) Cloning Channel Settings

① Select channel
(from cooling channel window)
② Click ‘Clone’ button
③ Check the target channel
3) Import Channel Settings

① Click Import button at channel window
② Select the csv file
4) Export Channel Settings

① Click Export button at channel window
② Select the file path to be saved

9.3 Pouring Basin
This function is for setting the working conditions of pouring basin.
Entity
Name: Display the name of entity set as pouring basin
Material: Pouring basin material
Melt Feeding
Melt-Amount: Volume of melt that fills the pouring basin initially for the ‘Feeding Continuously’ or ‘Feeding
Once’ option, or total volume of melt fed into the pouring basin for the ‘Feeding From a Ladle’ option
Melt Temperature: Temperature of melt that fills the pouring basin
How to Feed
1. Feeding Continuously(Constant Level): melt volume inside the pouring basin is constantly maintained
2. Feeding Once: Feeding stops after filling the pouring basin with a certain amount. Melt amount changes.
3. Feeding From a Ladle: Feeding the pouring basin from a ladle. The gate plane setting of the gate condition
is required.
Additional Pressure
Pressure value is set to put pressure to feed melt into unfilled spaces inside the pouring basin.

9.4 Stopper
This function is used to set the working condition of entity set as stopper.
Stopper Opening Condition Setting

Holding Time: Stopper opens after the user-defined time
Volume Fraction: Stopper opens after filling a particular entity with a certain amount of melt
In the ‘Volume Fraction’ setting, clicking ‘Select Entity’ button will display CAST type entity in the below
window. Select at least one target entity in volume fraction.

9.5 Stalk
This function is used to set the working condition of entity set as stalk.
Stalk-Out Time
Time when melt is decompressed
Solid Fraction
Standard solidification rate when melt inside stalk is removed
Air Temperature
Temperature of air to be filled inside empty stalk after melt has
been removed
*Note
When the solid fraction of a mesh is below the input value
(solid fraction), it is considered as liquid and the melt is re-
moved at the stalk-out time and stalk is filled with air.
9.6 Filter
Filter is used to analyze falling pressure & speed decline effect. This function is for setting the working con-
dition of entity set as filter.
Enable: Enable filter. When the filter function has not been
enabled, filter entity is the same as cavity entity.
Type: Select filter type. Click ‘Database’ button to select filter.
Material: Name the filter.
Permeability: Define permeability rate.

9.7 Exothermic Sleeve
This function is used to set the working condition of entity set as exothermic sleeves.
Preset
-Type : Set the Type of Exothermic Sleeve (refer to Type table)
User Define
(The Type is activated by setting User Define)
-Ignition Temp.
-Burn Time
-Heat Rate
-Dependency : Set detail of the Heat Rate

*Exothermic Type
Ignition Temp. Heat Generation Rate Burn Time

Item Density
[℃] [cal/s㎤] [sec]
4/7 0.75 500 2.604 144
Blind Type 5/8 0.75 500 2.500 150
6/9 0.75 500 2.343 160
7/10 0.75 500 1.923 195
8/11 0.75 500 1.666 225
9/12 0.75 500 1.562 240
Blind Dome N5 0.75 500 2.999 125
Type N6 0.75 500 2.500 150
N7 0.75 500 2.205 170
N8 0.75 500 1.829 205
N9 0.75 500 1.630 230
A80 0.8 500 1.904 210
A100 0.8 500 1.526 262
Open Type A120 0.8 500 1.270 315
A140 0.8 500 1.087 368
A160 0.8 500 0.950 421
A180 0.8 500 0.844 474
A200 0.8 500 0.759 527
A220 0.8 500 0.690 580
A240 0.8 500 0.632 633
A260 0.8 500 0.590 678

10
anySOLVER Launching Condition
10.1 Solution Method
anySOLVER consists of a SOLVER for simulating mold filling and a SOLVER for simulating the tempera-
ture/solidification process of melt, which work closely together to simulate the entire process from melt
filling to solidification.
1) Mold Filling
This function is used to set the condition factors of SOLVER that simulates melt flow.

Solution Target: Indicates the simulation target of SOLVER
Solver Type: Type of SOLVER (Hybrid Only)
Iteration Target: Variable that requires iterative calculation
Iteration Method: Iterative calculation method. Select Jacobi or SOR(default value)
Relaxation Factor: Relaxation factor used for iterative calculation
- Jacobi (0 < Relaxation Factor < 1), default value=0.8
- SOR (1< Relaxation Factor < 2), default value=1.8
Convergence Criterion: Convergence criterion for iterative calculation (<0.001, default value=0.001)
Maximum Iteration: Maximum number of iterative calculations (>50, default value=100)
Convection Scheme: Convective term processing method of Navier-Stokes Equation
- Central
- Fully Upwind (default value)
- Hybrid (0<Convection Scheme<1)
Ratio for Time Step (VOF): Time control factor for calculating the progress of free surface (courant number)
(0 < Weight for Time Step < 0.9, default value=0.9)
Slip Factor: Factor for determining the liquid slip velocity on the wall (-1 ~1)
-1 : very slow liquid slip velocity
0 : medium liquid slip velocity
1 : very fast liquid slip velocity
Filling End Criterion: Criterion value of completed filling
Treat the Solidified Volume as Obstacle: Solidified volume is treated as obstacle in flow analysis

2) Heat / Solidification
This function is to determine the control factors to launch SOLVER for simulating the heat/solidification
distribution of melt.
Solution Target: Indicate the simulation target

Solver Type: Hybrid (default value), (0<Value<1, default value=0.5)
Iteration Target: Variable that requires iterative calculation
Iteration Method: Iterative calculation method. SOR (default value)
Relaxation Factor: Relaxation factor used for iterative calculation, SOR (1<Relaxation Factor<2), default
value=1.6
Convergence Criterion: Convergence criterion for iterative calculation (< 0.01, default value=0.01)
Maximum Iteration: Maximum number of iterative calculations (>50, default value=100)
Weighting for Time Step: Weighting for SOLVER acceleration (default value=30)
Limit Time Step: Limit the maximum time step
*Note
For fluid analysis using simulation, the following three equations need to be analyzed:
- Momentum Equation, Navier-Stokes Equation

- Continuity Equation
- Volume of Fluid Equation

Iteration Method
According to the characteristics of numerical method, pressure equation is induced by modifying continuity
equation and iteration method is used to analyze the pressure equation. As stated earlier, there are two types
of iteration methods – the Jacobi and SOR (Successive Over-Relaxation) methods. The Jacobi method requires
more time until the convergence (the residual of the entire equation) falls below the user-defined conver-
gence criterion than that of the SOR method. However, it is effective in predicting symmetrical melt flow. On
the other hand, convergence speed of the SOR method is faster than that of the Jacobi method, although the
SOR method cannot guarantee symmetry of results.
Maximum Iteration
In the iterative calculation of pressure equation, there are cases where the calculation repeats infinitely when
convergence does not occur. In such cases, calculation is forcefully terminated to proceed to the next time
step when calculation reaches the maximum iteration number. If the maximum number is set too low (< 50),
calculation could proceed to the next step without sufficient convergence. Errors that have not been con-
verged could accumulate during this process, which could lead to decreased accuracy of calculation. If the
maximum number is set too high (> 150), analysis time takes too long from increased iterations. The rec-
ommended range of values in this program is 80-120.
Weighting for Time Step

Control the time step by using the weighting value created in the VOF equation. In the case where the free
surface of melt moves by more than one grid in the current time step, it becomes difficult to accurately pre-
dict the free surface through the VOF equation. In addition, divergence occurs without convergence. The
recommended range of values in this program is 0.5-0.9.

10.2 End/Output Condition
This function is for setting the end/output conditions.
1) End Condition
This function is for setting the end condition of simulation. There are four end conditions –Filling Rate,
Solidification Rate, Time and Max. Temperature.
Filling Rate: End simulation when filling rate reaches

the input value
Solid Fraction: End simulation when solid fraction
reaches the input value
Time: End simulation when time exceeds the input
value
Max. Temperature: End simulation when the maxi-
mum temperature of the domain falls below the input
value
2) Output Condition
This function is for setting the file save condition of simulation result after launching anySOLVER.
Type Select criterion variable for saving

result
(Filling Rate, Solid Fraction, Time)
Add Create save step
Single Create save step
Series Create series save step
Edit Edit a save step
Delete Delete a save step
Delete All Delete all save steps

*Note
- By marking the Append, user can append on the current input
value. (Without deleting existing list)
- Middle files (*.mid) are automatically created when anySOLVER

saves result files in the data interval set in the ‘Output Condition’.
- User can set the number of total step until step No. 999.
3) Shortened Output Condition

This function is for setting the cycle condition that is set ‘shortened output‘ at cyclic casting

10.3 Run anySOLVER
Clicking the ‘Run’ button in the Launching Condition will display the following anySOLVER window:
Clicking the activated button will start the simulation.

11Preference
This function is for setting user preferences including unit, user database and background color.
Select ‘File -> Preference’.
11.1 Color
Gradient Background: Enable/disable gradient back-

ground
Choose background color: Select background color
Highlight: Emphasize the specific entity
Show Bounding Box: Display the bounding box of the
highlighted entity
11.2 Entity Color
Enable : Enable entity Color 기능

Default Entity Color : Restore to the default setting

11.3 Unit
Unit System: Select MKS, CGS or BTU

Measurement Unit: Select measurement unit (inch, mm)
Importer Unit: Select CAD file unit (inch, mm)
11.4 Database
User Database:
Click button to select user database file (*.adb)
Default Material Spec.:

Select default material specification when displaying database ma-
terials

11.5 Misc.
Show the report after building mesh:

Display report after mesh generation
Enable Animation When Switching Viewpoint:

Enable/disable switching viewpoint display
Sensor Size Factor: Select sensor size factor

Section Line Size : Select section line thickness

12
Convert
File sizes can be minimized by converting V4.x files to V5.0 files and greater. File size changes can be checked
by opening existing *.gsc files and selecting ‘File->Convert’.
*Note
*.gscx files can be opened in anyPRE 5.0 and greater. (but not in anyPRE 4.0 and less.)

Contact Information
B-16F Woolim B/D, 583 Yangcheon-gu, Seoul, Korea 157-779

Tel. : +82-2-3665-2493
E-mail : support@anycasting.com

Anypre: A Pre-Processor of Anycasting

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anyPRE

AnyCasting™ Advanced Casting Simulation Software 001

002 AnyCasting User Maunal / anyPRE

AnyCasting™ Advanced Casting Simulation Software 003

Microsoft Windows™ is a registered trademark of Microsoft Cooperation.

004 AnyCasting User Maunal / anyPRE

1.1 AnyCasting Program

anyPRE, which has been developed based on MS-Window, is a casting process-oriented

Fast Meshing Algorithm

High Quality Viewing

Easy Setting of Simulation Condition

006 AnyCasting User Maunal / anyPRE

1) Import CAD File (STL file)

3) Set Simulation Condition

4) Set Basic Simulation Procedure

5) Set Optional Modules

AnyCasting™ Advanced Casting Simulation Software 007

7) Set the Launching Condition of anySOLVER

1.3 Input/Output Files

Project.gscx File that contains the information on tasks performed by anyPRE

Project.mshx File that contains mesh information

Project.mif6x File that contains RealFlow (sub-divided)mesh information

Project.prpx File that contains simulation conditions

Project.xml File that contains information on analysis option

Project.pxm File that contains information on analysis condition

008 AnyCasting User Maunal / anyPRE

2.1 Window Layout

① Menu & Toolbar

AnyCasting™ Advanced Casting Simulation Software 009

2) View Quick Menu

3) Switch to Select Mode

Basic mode; rotate Zoom in specific area

Pan Select mode

Zoom in/out Activate cross-section

Rotate screen axis Drag cross-section

010 AnyCasting User Maunal / anyPRE

2) Save Current User Viewpoint

Add User ViewPoint Add user viewpoint

Delete User ViewPoint Delete the current viewpoint selected

Load User ViewPoint Load saved file

Save User ViewPoint Create a file for the saved viewpoint

AnyCasting™ Advanced Casting Simulation Software 011

Perspective Projection Orthographic Projection

012 AnyCasting User Maunal / anyPRE

7) Set Background Color

Gradient effect is turned on

Background is in single color

AnyCasting™ Advanced Casting Simulation Software 013

Exit Close all windows and end the program

Undo Undo the Translate , Rotate action performed

Mesh Mesh Generation

Set Domain Set the domain size & symmetrical planes

Build Uniform Mesh Build uniform mesh

Build Variable Mesh Build variable mesh

Import Mesh Import built mesh

014 AnyCasting User Maunal / anyPRE

Basic Procedure Set basic simulation conditions

- Task Design Select casting process & analysis scope

- Material Setting Select material

- Initial and Domain BC Set initial/boundary conditions

- Gate Condition Set gate conditions

- Gravity Force Set gravity force and direction

Optional Modules Advanced Simulation Condition Setup

Open Open .gscx,.gsc file