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FLOW-3D Cast Training Course

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Day 1 – Hands On Sample Simulations

9:00 am – 5:00 pm

Training class attendees should bring a simple case with all material and process parameters necessary for training. We will work through these sample simulations on the first day in order to familiarize the training attendees with the user interface and how to set up simulations in FLOW-3D Cast.

Lunch will be provided by Flow Science

Day 2 – Understanding the Physical Models in FLOW-3D Cast

9:00 am – 5:00 pm

Lunch will be provided by Flow Science

Day 3

9:00 am – 12:00 pm

Day 3 will focus on any models that were not reviewed on Day 2, remaining issues with customer simulations and address customer questions.

Lunch on your own

1:00 pm – 5:00 pm

Optional Consultation (1/2 day or full day); You must be signed up for the consultation to attend this session

Course Details

Technical Foundations of FLOW-3D

The technical foundations of FLOW-3D are presented. Users will gain an understanding of which governing equations are solved, the structured gridding methodology, the TruVOF technique, and the FAVORTM method used for embedding complex geometries in a structured grid. 

Geometry Building and Property Definition

The concepts of geometry building are covered including the fundamentals of component and subcomponent creation. Various methods of creating geometry will be covered including FLOW-3D Castprimitives, and CAD files. Techniques for checking and fixing stereo lithography CAD files will be discussed. Users will learn how to judge adequate levels of mesh resolution so that the geometry is represented accurately without excessive use of computational resources.

Meshing Concepts

The basics of creating computational meshes will be covered along with best practices for meshing and multi-block meshing. The issue of adequate mesh resolution necessary to achieve accurate and efficient simulations will be discussed.

Boundary/Initial Conditions

Various boundary conditions will be discussed including slip/no-slip walls, free/partial-slip walls, wall roughness, velocity/volume flow rate boundaries, mass/mass momentum sources, pressure boundaries.

Modeling Ladles, Stoppers, and Shot Sleeves Using GMO

The motion of the ladle in a gravity pour process is commonly ignored and replaced by a simple boundary condition. Similarly, the shot sleeve in an HPDC process is commonly replaced by a velocity boundary condition. However, the motion of various components in casting processes may significantly affect the results of the casting process. The General Moving Object (GMO) model will be used to simulate moving components such as ladles and stoppers.

Types of Casting Processes Modeled in FLOW-3D

Physical Models and Components in Casting Simulations

Defect Prediction and Detection

Numerical Options

While the default numerical options in FLOW-3D Cast will typically produce an accurate and efficient simulation, there are situations where higher order numerical methods are warranted. A general approach to identifying when these higher order methods are required is developed.


The ½ day of training on Day 3 is designed to allow users to work on their casting problems with the help of a Flow Science support engineer. It is recommended that users clearly describe the problem they intend to work on by filling out the registration form as completely as possible.