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ProCAST 2009.1
Release Notes & Installation Guide
ProCAST 2009.1
The documents and related know-how herein provided by ESI Group subject to contractual conditions are to remain confidential. The CLIENT shall not disclose the documentation and/or related know-how in whole or in part to any third party without the prior written permission of ESI Group.
July 2009
CL/PRCA/09/01/00/A
CONTENTS
WHATS NEW 1
MeshCAST --------------------------------------------------------------------------------1 PreCAST-----------------------------------------------------------------------------------2
Mapping Tool-------------------------------------------------------------------------------- 2 Thermodynamic Databases ------------------------------------------------------------- 3
Solver ---------------------------------------------------------------------------------------5
Parallel Processing ------------------------------------------------------------------------ 5
Post-Processing--------------------------------------------------------------------------5
VisualCAST---------------------------------------------------------------------------------- 5
INSTALLATION GUIDE
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Product Availability -------------------------------------------------------------------- 23 Availability of the ProCAST DMP Version --------------------------------------- 25 General Requirements --------------------------------------------------------------- 26
SURVEY
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CONTENTS
WHATS NEW
WHATS NEW
This version is an update of version 2009.0 which corresponds to the first release of the new STL Mesh Generator. It also includes problems corrections and features improvements. For a complete list of the new or improved product functionalities, users are invited to consult the Whats New / Version 2009.1 section of the on-line product documentation.
MESHCAST
The Release of MeshCAST 2009.1 corresponds to the first release of a totally new surface mesh generator based upon STL files. The goal of this STL surface mesh generator is to offer the possibility (in most cases) to generate meshes of single volume or assemblies in a fully automatic way.
Please note that in the above picture, the model is "exploded" for viewing purposes only and that the resulting surface mesh is a fully assembled mesh of the different components using single click STL SM application. For more details, please refer to the "STL Mesh Generator" chapter of the MeshCAST 2009.1 Manual.
WHATS NEW
PRECAST
The following features have been added or improved: A new mapping tool is now available. It allows to extract Temperature, FVOL (filling information) and Porosity results from one calculation to an other, in the case where the two calculations were made with different meshes. New commands were added in the PreCAST Batch script (see the "Batch Preprocessing" section for more details).
Mapping Tool
A mapping tool was developed as mesh definition depends on process modeling goal. For instance, to capture high thermal gradients of a heat treatment quenching step, the mesh has to be refined in the gradient direction at the surface of the part compared with the standard solidification and fluid flow modeling. The principle of the mapping is the following for fields defined at nodes (like Temperature, FVOL or porosity): for each node of the target mesh, the corresponding element of the source mesh is searched. Then, the value of the target node is interpolated from the values of the vertices of the source element. Warning: The mesh from which the results will be extracted must be in tetraedra only (it is not allowed to have hex or wedges). However the target mesh (i.e. the mesh on which the mapping will be applied) can have any type of elements. The results mapping is working in the same way as the "Extract. The only difference is that one should select the "Mapping" button instead of the "Extract" one. All the rest of the procedure is identical.
WHATS NEW
The two following images are showing the result of a mapping of an HPDC casting from a coarse mesh (left) to a fine mesh (right).
One can see that the match between the two meshes is very good. The quality of the mapping is as good when going from a fine mesh to a coarse one.
Thermodynamic Databases
The following features have been added or improved: The Ni database was improved by the addition of Mn (up to 3%) and Cu. In addition, the quality of the calculations of the liquidus and of the gamma prime solvus were improved. The Fe database was improved in the case of alloys containing Nb (in conjunction with C).
WHATS NEW
The model for the calculation of the Yield stress of Al alloys was improved. Comparisons with experimental data are giving good results. Accordingly, the Yield stress of the "A356-Stress" and "A356-Visco-Stress" entries of the PreCAST database (stress.db) were modified to take into account this improvement. As the Yield stress is depending strongly on the microstructure, which is a result of different cooling rates, the A356-Stress single entry was replaced by four entries, which are valid for 4 typical cooling rates of 0.1, 1, 10 and 100 K/s. The following figure is showing the calculated Yield Stress for an A356 aluminum alloy, cast under different cooling rates (and thus having different value of SDAS). One can see the very strong effect of the microstructure on the Yield Stress.
The calculation of the Young's modulus of Cast iron was improved in order to take into account the influence of the graphite shape (i.e. for gray, compact or ductile iron). For this Young's modulus calculation, the effect of the graphite shape is triggered by the Mg content, according to the following amounts: Gray iron for Mg > 0.01%; Compact for 0.01% < Mg < 0.03%; Ductile iron for Mg > 0.03%.
WHATS NEW
SOLVER
The following features have been improved: The limitation of 10000 steps in Radiation calculation has been removed. A problem in the reinitialisation of the displacement in the case of stress and cycling was corrected.
Parallel Processing
Continuous efforts are being devoted to improve the scalability, repeatability and availability on various platforms of the ProCAST DMP solver. The following improvements have been made in ProCAST 2009.1: The THERMAL 2 option is now available in DMP. A problem of LPDC filling was corrected.
POST-PROCESSING
VisualCAST
The main features of release 5.5 are mentioned in the list below: - The "Scale dialog box" (e.g. to change the temperature scale for instance) can be opened automatically by a double-click on the scale. The liquidus and solidus are now displayed on the temperature scale. This display can be deactivated in the Scale dialog box (under Preferences - Datum Line) The plot of free surface information (like temperature, velocity ...) was improved. Improvements in the Exports are now available.
Please refer to the release notes of Visual Environment 5.5 under the section VisualCAST for the exhaustive list of improvements and new features.
INSTALLATION GUIDE
SOFTWARE INSTALLATION ON WINDOWS
INSTALLATION GUIDE
When the software installation is completed, the ProCAST product will be available in the Start/Programs/ESI group menu or in the ESI Group icon folder on the desktop.
Select System Settings tab Send all the information on the left part (Hostid Settings) to your local ESI support representative with the Save HOSTID Info to file option.
INSTALLATION GUIDE
Once you have received your(s) license file(s), it/they must be moved to the appropriate directory c:\flexlm on each machine with the file name pam_lmd.lic.
Using any usual text editor, edit pam_lmd.lic and change $PAMHOME to c:\flexlm\pam_lmd.exe on the line beginning with the DAEMON keyword Execute c:\flexlm\lmtools.exe
Select the Service/License file tab and select Configuration using Services
INSTALLATION GUIDE
Select the Configure Services tab, adjust parameters as below and click the Save Service button
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Select the Start/Stop/Reread tab and click the Start Server button
INSTALLATION GUIDE
After completing these installation steps, you may start using ProCAST. Additional specific FLEXlm documentation is also provided with the software on the installation CD-ROM.
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Both procedures perform the following tasks: 1. Install the software : Copy from the CD-ROM all the software files to the chosen location. Install the license file, Start the license daemons lmgrd and pam_lmd if needed, Install the license daemon startup scripts*. Set up the ESI Group software environment for each current user. 2. License management :
3. Customization : Tasks 2 and 3 can be performed later if the user does not want to do them immediately. After the installation, the files installed on the hard disk are organized in a directory tree as indicated below:
Head Directory
this is referenced as PAMHOME Installation Scripts...
MODULE 1
Executables, other files...
MODULE 2
Executables, other files...
Examples
Examples files, test cases...
LICENSES
License file
DOC
Electronic documentation
Version1_COMMON
Ressource files
platformOS1
Deamon and tool files
platformOS2
Deamon and tool files
Sufficient privileges may be required by the system during the installation of ESI Software products. Although no system library is updated in the process, sufficient privileges will be needed to mount the CD-ROM and to install the boot files to start the license server.
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When the installation is done, dont forget to quit the directory /cdrom before ejecting the CD-ROM from the drive.
PLATFORM PC Windows PC Linux MOUNTING Automatic Automatic SPECIFIC INSTRUCTIONS DISMOUNTING -
eject
# symbol is the SCSI Id number of the CD-ROM drive Device names in italics are site dependent
Graphical Installation
System requirement:
The installation through graphical user interface is available on Linux. In order to use the graphical installation, you need a X compliant window system available on your display. You must position the DISPLAY environment variable for display on the current screen, and if necessary allow this display using an appropriate xhost command on the display host. You also need about 5 Mb of free space in /tmp, in order to store graphical tools temporarily. To start the graphical software installation script, go to the /cdrom directory then type the following command:
./install.sh
To complete the installation follow the instructions displayed in blue colour in the dialog boxes presented by the installation tool. After the graphical tools are loaded in /tmp, the main dialog box window appears:
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INSTALLATION GUIDE
Click the Install software button. It will highlight the Next button to continue. Click the Next button to continue the software installation. Click the Cancel button to abort/exit the software installation.
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INSTALLATION GUIDE
This dialog box is used to specify the installation directory. By default, the text field of the installation directory is filled with the previous pathname of ESI Group software installation directory if any. Two possibilities are available to select a new software installation location on the system: or Click the Browse button to select another software installation location Directory selector dialog box for using it). (see Click on and fill the text field with a valid pathname directory (read, write, execute permissions are required),
Click the Next button when you are satisfied with the software installation directory selected. Click the Previous button to go back to the main dialog box of the software installation.
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Package Selection:
INSTALLATION GUIDE
This dialog box is used to select all the software package(s). Select all the platform package(s) you wish to download on the system by clicking on the toggle(s) then click the Next button to continue. Note that, if not already done, the flexnet_v10.1.3 package should also be installed for all platforms. A scrolled window is displayed showing the downloading of files. When the downloading is finished, the Close button will be highlighted. Click Close to continue.
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INSTALLATION GUIDE
The main dialog box window appears again to perform the next steps, the license installation and/or Customization of the software environment. Click the Exit button if you wish to perform the License installation and software customization later. Click the License management button to install the license. A license file is needed to perform this task. For more detail, please and see the Installation of the license section. Click the Define environment button to customize the software environment. For more detail, please see the Customization section.
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./paminst-gui.sh
lic or ./paminst-gui.sh
install_lic
After the graphical tools are loaded in /tmp, the following assistant window appears:
INSTALLATION GUIDE
The specified directory in the text field should contain a licenses subdirectory with write permission to highlight the Next button.
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Click the Next button when the installation directory pathname is selected. The license file is installed in the right location and the following dialog box appears:
INSTALLATION GUIDE
Click the Get another license file button to select a new license file.
Click the OK button to find the new license file on the local disk. A new file browser window appears.
By default the file filter is set for find PAM license file. Select the new license file then click the Open button to validate the selection.
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A small window pops up displaying the checking result of the selected license file with the host id.
INSTALLATION GUIDE
The dialog box of license file selection will be displayed again and filled with information corresponding to the selected license file.
Click the Save new file as current button. The new license file is installed and the Next button is activated to continue. Click the Next button to start the license daemons.
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INSTALLATION GUIDE
Click the Start daemon now as current user button to start the daemon. Additional specific FLEXlm documentation is also provided with the software on the installation CD-ROM.
Customization
The ESI Group software installation script paminst.sh can be used for customization. This customization is done with pamcust.sh which can also be used separately. To perform the customization separately: Log in on the machine on which you want to perform the customizations, Change directory to the $PAMHOME directory where the installation has been done, Type ./pamcust.sh and follow the instructions.
The customization script creates definitions to allow access to the ProCAST executables and configuration files for all users or for selected users, depending on the method selected. The software configuration is defined in the following files: psi.Cenv for csh and derivatives, psi.Kenv for ksh and derivatives, Psi.Baenv for bash.
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Note that sh is not supported due to its lack of functionalities necessary for ESI Group products. We recommend sh users to migrate to ksh which preserves sh syntax and habits. The customization procedure will automatically update the .cshrc, .profile or .bash_profile files accordingly, as shown below. C Shell - .cshrc file
### PAM-SYSTEM begin ### # # PAM-SYSTEM Software environment # setenv PAMHOME /usr/people/test setenv PAMENV $PAMHOME/env-uname if ( -r $PAMENV/psi.Cenv ) then source $PAMENV/psi.Cenv endif ### PAM-SYSTEM end ### ### PAM-SYSTEM begin ### # # PAM-SYSTEM Software environment # PAMHOME=/usr/people/test; export PAMHOME PAMENV=$PAMHOME/env-uname; export PAMENV if [ -r $PAMENV/psi.Cenv ]; then . $PAMENV/psi.Kenv fi ENV=${ENV:} If [ -z $ENV ]; then ENV=$HOME/.kshrc; export ENV fi ### PAM-SYSTEM end ### ### PAM-SYSTEM begin ### # # PAM-SYSTEM Software environment # PAMHOME=/usr/people/test; export PAMHOME PAMENV=$PAMHOME/env-uname; export PAMENV if [ -r $PAMENV/psi.Cenv ]; then . $PAMENV/psi.Kenv fi BASH_ENV=${BASH_ENV:-} If [ -z $BASH_ENV ]; then ENV=$HOME/.bashrc; export BASH_ENV fi ### PAM-SYSTEM end ###
INSTALLATION GUIDE
The same procedure must be repeated for the customization of each candidate user.
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GETTING STARTED
Starting the Software
INSTALLATION GUIDE
Note that access to previous versions of ProCAST is possible with modified aliases. For instance, type cast090 for the ProCAST 2009.0 software manager.
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Processor
OS Windows 2003 Windows XP Windows Vista Windows 2003 x64 Windows XP x64 Windows Vista x64 Redhat 9.0 (compatible) Redhat EL3 and higher Redhat EL3 and higher
DMP yes
AVAILABLE PLATFORMS AND PRE-REQUISITES
Intel / AMD
64 bits
yes
Linux
Intel
32 bits
yes
Intel / AMD
64 bits
yes
User Interfaces:
Vendor Windows
OS Windows 2003 Windows XP Windows Vista Redhat 9.0 (compatible) Redhat EL3 and higher
Linux
Intel / AMD
32 bits
Remarks:
Specific MeshCAST executables are available for 32 and 64bits platforms. The Parasolid interface is only available on 32bits platforms.
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VisualCAST:
Vendor Windows
OS Windows 2003 Windows XP Windows Vista Windows 2003 x64 Windows XP x64 Windows Vista x64 Redhat EL3 Suse 9 Redhat EL4 Suse 10
Linux
Refer to the Visual Environment product documentation and in particular to the VisualEnvironment-5.5_InstallationGuide.pdf document for detailed information on hardware requirements.
AVAILABLE PLATFORMS AND PRE-REQUISITES
Remarks:
The ProCAST 2009.1 package requires the installation of the VisualCAST 5.5 version.
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The HPMPI: Message Passing Interface version 2.2.5 on Linux and version 1.1 on Windows (copyright HP) are used and required runtime libraries are included in the software package. The PETSc: Portable, Extensible Toolkit for Scientific Computation (Copyright 19952004, University of Chicago) version 3.0.0. is used on all platforms and required runtime libraries are included in the software package when appropriate. The ParMetis version 3.1.1 is used on all platforms for dynamic domain partitioning and required runtime libraries are included in the software package when appropriate. Specific parallel executables are also available upon request for the following hardware platforms: Linux 64 bits IA-64 Itanium Redhat Linux Advanced Workstation 2.1 using HPMPI, PETSc and ParMetis libraries (Linux kernel above 2.4.18).
For additional information, refer to the User Manual and in particular to the Parallel solver / Use of the parallel solver section for a detailed description of the necessary commands.
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GENERAL REQUIREMENTS
In the list below, some global recommendations are given for running ProCAST on the various platforms. Please consult with the local ESI Group support for more information. A minimum of 2 Gb of memory is required to operate the software. More memory is however recommended for large industrial applications. Consult the information provided in the installation directory $PAMHOME/info/README_ProCAST_2009.1 for a complete list of run time libraries and pre-requisites corresponding to each platform. For access to on-line documentation, Mozilla (or equivalent) is required on all Linux platforms. OpenGL hardware graphic accelerator is highly recommended. Screen resolution should be set to at least 1280*1024 with small fonts selected.
AVAILABLE PLATFORMS AND PRE-REQUISITES
For optimal graphics performance on Windows platforms, the installation of the latest graphics drivers is recommended. 3 button mouse is required (middle mouse button required for dynamic rotations in graphics window with VisualCAST). ProCAST 2009.1 requires the installation of the VisualCAST 5.5 version. On Linux and Windows platforms, the icc compiler version 11.0 is used for the solver compilation. To compile User functions, the following compilers should be available on the target platform: Windows : Microsoft Visual C++ 2008 Express Edition (free of cost as of February 2009) Linux : Intel icc compiler version 11.0 or gcc compiler version 3.2.3
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SURVEY
The information you will provide is of highest value for us in order to better understand your expectations and to enhance our services. Therefore, we warmly thank you in advance for the time and assiduous attention you will devote to filling in this form and for sending it back by fax (+41 21 693 4740), post mail to Marco Aloe / Calcom ESI / Parc Scientifique EPFL / PSE-A / CH-1015 Lausanne / Switzerland or by email to support.cast@esi-group.com.
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GENERAL INFORMATION Name of the company Field of activity Department or service Address 1 Address 2 Your first and last name Your title or function Your direct phone and fax E-mail INFORMATION ON THE PRODUCT FEATURES Operating system (Windows, Linux, other) How long have you been using this product? How many people are using this product?
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Your assessment : 3 3.1 3.2 3.3 3.4 PERFORMANCE OF THE PRODUCT Meshing time from CAD import Pre-processing effectiveness / relevancy Simulation time Solver stability : 3.4.1 3.4.2 3.4.3 3.4.4 3.4.5 3.5 thermal simulation fluid-flow simulation stress simulation simulation (***) simulation (***)
Accuracy and relevancy of the results according to each feature : 3.5.1 3.5.2 3.5.3 3.5.4 3.5.5 thermal simulation fluid-flow simulation stress simulation simulation (***) simulation (***)
Post-processing effectiveness and relevancy General graphic rendering of software User-friendliness, comprehensibility, ease of navigation in menus User manual, release notes (***) Please mention the additional simulation features, if any, you work with
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