Important release notes and tips

1. Exothermic data for Foseco Kalminex sleeves: T burning = 400C; Q burning = 2200 KJ/Kg; Burning time = 30 seconds. This results in a burning temperature of 1650C (Which has been measured). Note that there is a rather big variation on exothermic material from batch to batch. Set the exo values so it will be within the minimum specification. 2. Segregation of steel 2nd solid phase in the database is Austenite. The carbon content differences in the casting are shown under simulation. 3. Segregation of Ductile and grey iron 1st solid phase is Austenite, 2nd solid phase is Cementite and 3rd solid phase is Graphite. The carbon content differences in the casting are shown under simulation. 4. Segregation of Aluminium 1st solid phase hard solution of silicon + aluminium, 2nd solid phase is hard solution of aluminium+silicon. The silicon content differences in the casting are shown in simulation. 5. Modulus calculation for calculation of feeders should be done with the specific mould material called Modulus_calculation to ensure more accurate results of the modulus. 6. Multiple processor support works for 2 or more processors. One extra processor will increase the calculation speed with 50 80 %. 7. Note that in the 3D import module after you have turned and positioned your casting you must press the Fix Position! button. 8. The gating alternative circle must be used for traditional type of Tiltpouring. This is the case if you are using a pouring basin and start with the mould in horizontal position. If the section is used, the meshing will be wrong and the whole casting will not be filled. 9. Tiltpouring is enabled for the following filling alternatives: Bottom pouring ladles and Ladle pouring over lip. 10. CLF Pressure For high pressure diecasting the Forcing Through temperature is removed. Instead we are now using CLF Pressure. The CLF Pressure value for High Pressure Die Casting should be around 1 -10 %. This means that we overrule the CLFd and let it feed longer due to the pressure from the piston. Note that Feeding pressure should be the actual 3rd phase after pressure that you set on the machine. To finetune the shrinkages change the CLF Pressure up if there are too little shrinkages and down if there are too much. Compressibility should be set to 50. Note that for high pressure die casting the Gravity influence should be set to 0 . 11. 4-views Zoom to fit Window. When using the 4-views command there have been problems in removing this viewing alternative. Now there is a function available directly by right-clicking on the mouse. Just click Zoom to fit Window in the window part that you want to keep. 12. NovaStress Start calculation when a solid skin is formed around the casting with a maximum liquid content of 10 %. This will give you more exact deformation values. Simulate solidification down to around 400 100 degrees depending on mould temperature. Very important is to save both by percent liquid phase and by maximum temperature during solidification.

13. Setting feeding point for high pressure die casting Set the feeding point in the middle of the tablet and centered. 14. Setting of filter The improved filter function with automatic calculation of filter factor works mainly for extruded filters. For foam filters the pore diameter can also be used but then the average diameter should be used. In all cases the filter thickness should be the actual one and the filter in NFS 2.92 should be modelled to the same height as the real one (Which is made automatically). 1. If you want to use foam filters the following filter friction factors should be used: 10 PPI = 16 pores /cm2 (Average pore diameter ~ 2.0 mm); 20 PPI = 64 pores/cm2 (Average pore diameter ~ 1.05 mm); 30 PPI = 144 pores/cm2 (Average pore diameter ~ 0.7 mm). 2. New rotation fuction: Use hotkey to switch between rotation, pan and zoom. CTRL + Left mouse button Rotation CTRL + Right mouse button Pan/move CTRL + Mouse wheel Zoom 3. Use the new cutting function in Initial Settings / Build mesh to cut off box in different directions for enabling imported cooling channels to end on the boundary planes.

a) b) c) d) e)

Select plane where you want to cut. Go to Build mesh Select Box dimension tab Tic off Set symmetry plane boundary conditions Press Apply (in the same row as point d)

f) Press Apply at the bottom of the menu. 4. Niyama settings/evaluation for different materials: Cast Iron: 0 0.25 = Severe 0.25 0.50 = Less severe 0.50 0.75 = Least severe 0 1.0 = Working interval 0 0.5 = Can be seen on x-ray 0 0.30 = Working interval

Steel:

Aluminium:

Copperbased: 0 1.30 = Working interval 5. In the Browser module there is a menu alternative called Play. If you open this menu you will find Rotation options. This means that if for example you set a 5 degree step option, it will rotate the casting by 5 degrees for every saved step. This is the case if you use the play functions. 6. In order to simulate a closed mold during thermal cycling increase the air temperature to 200 degrees during that phase. 7. Adjustment of shrinkage volume for HPD will be realized now by 2 parameters: Percolation threshold (CLFd) and CLF pressure (Percolation threshold under pressure). Localization of zones is determined as before by the Percolation threshold, and the shrinkage volume will be determined by the Percolation threshold under pressure (CLF pressure). If to set the thresholds equal then the volume of shrinkage will be the same as in 2.8. If the volume is too high than you should set CLFpressure lower than CLFd.

8. Explanation Work of the new HPD Filling chamber alternative:

a b c d

a. Cylinder diameter will be automatically detected if gating point is positioned there. b. The cylinder length should be the same as stroke length. c. Here you should put in the same value as the Casting mass. d. Stroke length to reach 100 % fill means the distance the piston has to move before the chamber is filled 100 %. e. Piston movement in phase This is particular movement of the piston for this phase. This means that you should not use the complete movement.

Phase 1: Filling completely of chamber Phase 2: Filling of the ingate Phase 1 + 2 = to the traditional 1st phase Phase 3: Filling of the cavity Example: The casting above should be filled as follows: Velocity 1st phase: 0.5 m/s Piston movement during the complete first phase 302 mm Velocity 2nd phase: 2.5 m/s Setup: 1st filling phase: Movement in phase 232 mm(calculated by the system) 2nd filling phase: Movement in phase 60 mm, Velocity in phase 0.5 m/s 3rd filling phase: Movement in phase 450 (232 +60) ) = 148 mm, Velocity in phase 2.5 m/s. 9. Simulate cycling with a closed mould. Increase the media temperature during the cycling around 150 200 Degrees. 10. Radiation factor For a Medium material one can set the radiation factor. This factor sets the ability for heat radiation inside the mould to work. For a normal gravity casting it should be set to 1, but for a Lost foam pouring it should be set to 0 since no radiation inside the mould can take place due to the smoke in the cavity.