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BACK TO MAIN MENU   Over time, a number of special purpose utilities have been created for use with SOLIDCast. These programs cover many topics; some are used in model building, some in file handling/conversion, and others for specific special purposes. These utilities have been bundled with the SOLIDCast package. When you install SOLIDCast or

SOLIDCast   UNIT 1: Overview of the Simulation Process UNIT 2: System Installation and System Considerations UNIT 3: Setting System Parameters UNIT 4: Selecting the Casting Alloy UNIT 5: Cooling Curves and Volumetric Change Curves UNIT 6: Customizing Curves for Cast Irons UNIT 7: Selecting Mold Materials UNIT 8: Heat Transfer Coefficients UNIT 9: Importing

BACK TO MAIN MENU   When you first install SOLIDCast it is a good idea to check out and properly set your System Parameters. A moment spent now making sure things are correct can head off many problems before they get a chance to start. From the main SOLIDCast menu click on Tools…System Parameters. There

BACK TO MAIN MENU   Solidification modeling refers to the process of simulating, on a computer, what happens when a casting is poured into a mold and the metal cools and solidifies. By simulating this process, we hope to predict potential defects in the casting and redesign the process to eliminate the defects, before making

BACK TO MAIN MENU   Hardware Minimum Requirements (SOLIDCast without OPTICast or FLOWCast, or for small mesh node counts) CPU: For best results, choose a CPU with 4 cores. Intel Core i3, i5 or i7, any generation, Nehelem microarchitecture or later Intel Xeon CPU, Nehelem microarchitecture or later AMD equivalent 8 GB RAM 500GB Hard

BACK TO MAIN MENU If Model does not appear on the menu bar, select File New Model. Select Model, and then select Materials List. Click on the Casting Material tab. You will see a display similar to the following: This shows the currently-selected casting alloy and its properties. Note that Initial Temperature refers to the

BACK TO MAIN MENU   To see the cooling curve and the curve describing the volumetric change (shrinkage or expansion) of the selected alloy, click on Model… Materials List and then click on the Cooling Curve tab. You will see a window as follows: The white line indicates the cooling curve (Percent Solid vs. Temperature),

BACK TO MAIN MENU   For ductile irons and gray irons, the system allows you to customize the cooling curves based on the specific composition of Carbon, Silicon and Phosphorus in your alloy. The system also calculates the CFS point and overall amount of shrinkage during solidification and makes automatic adjustments to the shrinkage curve,

BACK TO MAIN MENU   To select materials for use in the mold, from the menu bar select Model… Materials List and then click on the Mold Materials tab. You will see a window that appears as follows: In this screen, the materials that are available to use in a model are shown in the

BACK TO MAIN MENU   Heat Transfer Coefficients are values that indicate how well or how poorly heat is transferred across a SURFACE, as opposed to heat flow WITHIN a material. For most sand and investment castings, we are concerned primarily with how well heat is transferred from the exterior surface of the mold. The

BACK TO MAIN MENU   The primary method for importing three-dimensional CAD data into SOLIDCast is through the use of STL files. STL files were originally developed for rapid prototyping (STL = STereo Lithography). They consist of a representation of the surface of a part as a series of small triangles. Most 3D CAD systems

BACK TO MAIN MENU   SOLIDCast allows you to create basic geometric shapes that can be part of a casting model. Some simple castings may be created entirely with this type of shape. In other cases, it may be feasible to use basic shapes such as cylinders to add risers to a casting model. It

BACK TO MAIN MENU In SOLIDCast, the display controls are located as icons across the top of the model window. These display controls appear in a bar as follows: The meanings of these icons are as follows:         Switches between a shaded rendered view and a wire-frame view of the casting.       Toggles the background

BACK TO MAIN MENU   Once you have a model loaded and materials selected, the next step before running a simulation is to generate a mesh. This is done by selecting Model… Create Mesh… from the menu bar. The system will display the meshing screen. This is where you describe how the mesh is to

BACK TO MAIN MENU   To calculate weights, you must have previously meshed a model. The mesh name appears on the project tree on the left side of the screen, as shown below:   To perform a weight calculation, highlight the mesh name and select Mesh Weights. The following window will appear: Note: To obtain

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