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NovaFlow & Solid CV High Pressure Die Casting

Faster and more

accurate simulations
NovaFlow & Solid CV is a mould filling and
solidification simulation package based on
advanced fluid flow and heat transfer theories.
New meshing technology and new advanced numeric models, Control Volume Meshing (CVM) make it
the most efficient simulation package on the market.
NovaFlow & Solid CV requires less than one hour
to set up a complete simulation including start-up,
meshing and running. The resulting simulation will
be extremely accurate in accordance with your 3D
drawings.
Simulations
Most of the casting methods on the market can be
simulated such as gravity sand casting, gravity
permanent mould, low pressure die casting, high
pressure die casting, lost wax method, tilt pouring
and lost foam process. Commercial alloys can be
simulated such as grey- and ductile iron, steel, aluminium alloys, copper-, zinc- and magnesium-based
alloys, super alloys, all types of mould and core
materials that exist on the market and exothermic
materials as well as chills.
Simulations visualise the consequences of a certain design of gating systems and moulds. Casting
defects, such as oxide inclusions due to excessive
turbulence, cold-shuts, shrinkage cavities and slag
inclusions, can be avoided by optimising the design
of the gating and venting system.
CVM technology
CVM technology allows the surface of the 3D model
to control the shape of the mesh elements on the
border of the casting. This creates cubic elements
inside the casting and border cells on the boundary
of the casting.
Advantages
CVM technology has the following advantages in
comparison with FDM/FEM methods:
For most castings, simulation time is reduced to
around 10 percent with the same or improved ac-

curacy (FDM)
A higher accuracy in simulation, due to perfect description of the 3D model. All sections are correct
in size (FDM)
Less cells are needed to define the casting geometry which ensures faster simulations and smaller
result files (FDM)
The meshing process is completely automatic and
only takes seconds (FEM)
Advanced calculations are enabled, such as gas
flow, contact task (stress) or full mould process
(FDM)
Unique functionalities
In addition NovaFlow & Solid CV has the following
unique functionalities:
Option to use the ATAS thermal analysis system
for updating the alloy database in NovaFlow
& Solid CV, with actual data based on poured
samples. The effect of graphite expansion can be
accurately modelled
A formula function for creating your own criteria,
for example shrinkage prediction. This function
also enables the calculation of Dendrite Arm Spacing (DAS) and matrix
With the particle tracer function, users can more
accurately simulate flow behaviour and also
induce slag particles into the melt for tracing
Gas calculation which enables back pressure and
vacuum permeability
Use of moveable piston in chamber in order to
simulate the filling in first phase
Dual mesh function. Use different mesh for filling
and solidification

NovaFlow & Solid CV High Pressure Die Casting

Temperature Distribution

Air Contact

3D Import

Simulation

Import of binary and ASCII STL files and STEP files

Import of cooling channels and filter
STL fixing
Boolean functions
Extension functions
Positioning functions

Fastest and most accurate simulation package on the market

Multiple processor support
The easiest package for setting up and rerunning a simulation
Calculation of velocity, pressure, temperature, liquid phase,
local solidification time, wall contact, air contact, air pressure
and air entrapment
Macro shrinkage prediction with the shrinkage criteria and
micro shrinkage prediction with the Niyama criteria
Mesh size is limited to RAM. In Windows 32-bit 3 GB is possible. With 64 bit, the limitation is more or less removed

Includes advanced database based on constitution diagrams

Accounts for gravity during simulation
Calculates air gap formation or heat transfer coefficient
Import cooling and heating channels
Cycling simulation with multiple cooling phases
Saving mould temperature from a rough meshed cycling
simulation into a fine-meshed flow & solid simulation. Enables
extremely fast cycling simulations
Velocity trigger function (set in the 1st and 2nd phase)
Trigger filling time. Setting velocity in 1st phase and filling time
in 2nd phase
Piston position controlled velocity with moveable piston
The 3rd phase, i.e. the compression phase, can be simulated.
Accurate shrinkage predictions can be obtained.
Vents, for calculating air bubbles
Particle trace function (tracking of slag inclusions) with flow
length and age
Sensors measuring velocity, pressure, temperature, liquid
phase and cooling rate at a certain point
Flow meter measuring the efficiency of an ingate
2D and 3D velocity vectors

Results presentation
Powerful browsing and slicing in x, y and z directions
Built-in animation functions for presentation of results, creation of AVI and real time AVI movie files as well as WMV
Two or more simulations can be viewed simultaneously in the
browser
Printing facility in all modules
Possibility to save simulations in BMP or JPEG formats in each
module
Automatic report generator in doc-format

Hardware Recommendations
PC with QUAD Core (4) or 6 or 8 core processors (Multiple
processor support)
Highly recommended: Pentium XEON processors
Microsoft Windows Vista or 7, 64-bit (runs also on 32-bit
version of Windows but with limited RAM memory <3.3 GB)
16 GB RAM
200 GB free hard disk space
Highly recommended: Solid state drive as primary disc where
simulation should run and be stored during simulation,
normal HDD for storage after simulation as secondary disc
Minimum screen resolution 1280 x 1024 with at least 16-bit
colour depth
DVD-R/RW
Graphics card supporting OPEN GL support
3D mouse for rotation, move and zoom. System supports 3D
connexion Spacenavigator

NovaCast Systems AB . Soft Center, SE-372 25 Ronneby, Sweden

Tel +46 457 46 58 00 . Fax +46 457 156 22 . info@novacast.se . www.novacast.se

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Characteristics