The Filling Tab contains two main areas, Filling Parameters and Simulation Parameters, as shown below:
Filling Parameters show the inflow speed, pouring temperature and stop flow temperature. The first two parameters are extracted from the meshed model, and are display-only. They cannot be modified by the user. The Stop Flow Temperature, Variable Fill Rate and Simulation Parameters can all be adjusted by the user.
Stop Flow Temperature – This is the point at which metal flow stops during a filling simulation. This will default to the Critical Fraction Solid (CFS) point specified in the SOLIDCast Materials List for the given casting alloy. However, it can be modified by the user, to simulate the effects of ‘castability’ and better predict misrun conditions. The following photograph and figures show a misrun condition in a copper-base casting, and two views of the FLOWCast and SOLIDCast predictions.
Variable Fill Rate – If this box is checked, then FLOWCast will run a variable fill rate simulation, using data provided from the SOLIDCast Bottom Pour Ladle Utility. This utility creates a file called FlowRates.fil, which contains data as to how the filling rate changes over time. It is also possible for a user to create this file manually, to simulate other types of variable filling rate situations.
CFL – This is a parameter that is adjusted only for extremely large castings, of 30 tons or more, with multiple minute pouring times. Use the default value of 0.7.
HTC Weight – This factor allows you to fine tune for your process, to better predict filling problems such as misruns. For sand or investment casting, we recommend a starting point of 0.6, and for permanent mold castings, 0.3. If a simulation predicts a misrun that does not occur on the shop floor, you can reduce the HTC Weight. If the simulation does not predict a misrun that does occur on the shop floor, you can increase the HTC Weight.
Save every % filled (full save) – This tells the system how often to save the complete data set, which is used for re-starting a simulation, and for plotting of velocity and pressure. The range for this value is from 1% to 20%. Remember that saving data takes quite a bit of disk space. Normally, the main filling phenomena take place earlier in the filling sequence, so you may want to initially save data at, say, every 1% until 50% full, then reset to every 5%. This data is used after a simulation is complete to create animations of the filling process.
Save every % filled (anim only) – This tells the system how often to save temperature data only, for use in making movies on the Animat. Tab. Since most people are interested in temperature data, you can specify a smaller number for temperature data, and a larger increment for the full save of velocity and pressure data. This may help to keep file sizes smaller, by not saving all the data in small increments. The range for this value is from 0.2% to 2.0%.
Update display every % filled – This tells the system how often to redraw the screen during a simulation run. The default value is every 0.25%. As a simulation is run the screen is updated based on this parameter. If you are not actually watching the simulation, the value isn’t really important. Since this data is not saved, the value used here will not affect the size of the saved simulation.
Stop simulation at % filled – This tells the system when a simulation is considered complete. Most of the interesting phenomena during filling take place fairly early on, so you may wish to stop a simulation before filling is complete. The default value is 100%.