Casting
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Casting Tool
What can we do with Casting tool?
Generate FE surface mesh, with specified target length, in the middle position even in the
most complicated models.
What are the advantages of the new Casting tool?
-
Automatic generation of FE surface mesh of high quality.
Automatic perimeters creation that allows FE to be
treated and improved like Geometry.
Direct association of the created FE mesh to the initial
geometry via the Align entities.
Easy align process.
Real time calculation of middle position and nodal
thickness in every mesh action.
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Casting v20.1.x
Run Casting Algorithm
CTRL+A
Activate Faces>Mid.Surf>Casting function.
Input the values for Minimum thickness, Target element length, Collapse
perimeters distance and Collapse junctions distance.
More advanced parameters that can be set up for an optimal result.
After few seconds the casting algorithm is finished.
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Casting v20.1.x
Casting Options
CTRL+A
Minimum thickness is
the minimum thickness
that exists in the model.
Collapse perimeters
distance is the
distance under which
perimeters will
collapse (it can be
given as a percentage
of the target element
length).
Collapse junctions
distance is the distance
under which T- junctions
will collapse (it can be
given as a percentage of
the target element
length).
Y-result if this
option is used, Yjoints will get a
‘mathematical’
middle treatment.
Align Entities will
not be created!
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Casting v20.1.x
Casting Options
CTRL+A
On Features tab the user can specify Mesh Treatments for holes.
This widow has direct communication with global Mesh Parameters, so the user needs to set
them only once.
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Casting v20.1.x
Casting Options
CTRL+A
Connect weldings with thickness ratio will extend and connect the meshed
parts after the Casting function is executed. Sharpen fillets with radius<
option from Parameters tab can be used with Connect weldings for a better
result.
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Casting v20.1.x
Align Manager
•
•
•
•
The FE mesh generated is associated with the geometry. Associated
shells are called Align Entities.
Handling of the associated shells (Align Entities) is done via Align
Manager.
To invoke the Align Manager go to Faces>Mid.Surface>Align Manager.
Automatically the Draw Mode changes to USER and Align entities are
colored according to their type.
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Casting v20.1.x
Describing Align Entities: Plane, Middle
• When an Align Entity is selected its associated geometry is
highlighted on the screen.
• Notice that FE mesh are positioned in the middle of the
associated geometry.
• Shells automatically obtain the correct nodal thickness.
CTRL+A
Align Entity type: Plane
Shells lie on a specific plane (between planar
faces).
Plane entities are shown with red color.
Align Entity type: Middle
Shells lie on a specific curved surface (between
curved faces).
Middle entities are shown with green color.
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Casting v20.1.x
Describing Align Entities: Empty
CTRL+A
Align Entity type: Empty
Shells that the casting algorithm could not decide
where to assign them. These are the areas that the
user has to fix (associate) manually.
Empty entities are shown with brown color.
! Note: After the execution of the casting algorithm, Plane, Middle
and Empty Align entities are generated. However, there are 2
more Align entity types Offset and Cylinder.
All of them can be used to fix the result that was generated directly
after casting.
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Casting v20.1.x
Describing Align Entities: Cylinder, Offset
CTRL+A
Align Entity type: Cylinder
Shells assigned to a specific cylinder with defined
axis points, defined radius and thickness (on both
cylinder’s bases).
Cylinder entities are shown with purple color.
Align Entity type: Offset
Shells are offset from specific face(s) and they lie in a
defined distance from them (the user can pick the
thickness from screen).
Offset entities are shown with blue color.
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Casting v20.1.x
Describing Align Entities: Perimeters
Perimeters type: Faces
Perimeters lie exactly on one or more faces. After
casting tool runs, all single bounds are
automatically assigned to their boundary Faces.
Faces type perimeters are shown with red color.
Perimeters type: Offset
Perimeters are a projection of one or more CONS.
Offset type perimeters are shown with green color.
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Casting v20.1.x
Describing Align Entities: Perimeters
CTRL+A
Perimeters type: Sharp
Perimeters do not lie on a specific surface or line
but it is a Sharp edge. Sharp edges are
automatically recognized and marked by casting
tool in order to achieve a better result. Sharp type
perimeters are shown with purple color.
Perimeters type: Empty
Perimeters do not lie on a specific surface or line.
These are the perimeters that casting algorithm
could not decide where to assign them. Empty type
perimeters are shown with brown color.
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Casting v20.1.x
Align Command
CTRL+A
Press Align, select the shells with box selection
and confirm with middle mouse click.
! Note: With Align command the nodes are placed in the middle and the
nodal thickness is recalculated.
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Casting v20.1.x
Align Manager Options
By opening the Options tab of the Align Manager five checkboxes
are available.
• Align mesh after modifying Align entities: After any
modification or creation of Align entities, Align will
automatically be applied.
• Real thickness: Nodal thickness will be calculated from actual
geometry, not from the definition of Align entities
• Reconstruct mesh after Align: After Align, automatically
reconstruction will be applied (the zones of reconstruction can
be selected by the user).
• Intersection angle for new entities: The user can also define
the Intersection angle limit for the new Align Entities.
• Auto show or hide solid description when defining Align entities:
When the user defines a new Align entity the geometry will
automatically pop-up (the visibility of geometry should be
enabled). After the definition it will hide again.
! Note: By default all of these checkboxes, except
Real thickness, are checked and the Intersection
angle limit is 20°.
• Draw Align entities’ definition when selected: When the user
selects Align entities, their geometrical definition will
automatically highlight.
• Align nodes after modifying mesh: After EVERY mesh
modification automatically Align will be applied.
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Casting v20.1.x
Align Manager Options
Real thickness
Real thickness disabled
Real thickness enabled
Align entity definition
Enabling Real thickness option causes nodal
thickness to be calculated from actual geometry,
not from the definition of Align entities.
! Note: Nodal thickness is re-assigned to elements every
time Align function is executed!
! Note: Align function is automatically called by Align
entity modification and mesh improvement actions (as
long as the respective options are active)!
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Casting v20.1.x
Align Manager Options
Align nodes after modifying mesh
Opposite Path selection
Apply Elements>Split.
Nodes automatically
popped up in the middle.
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Casting v20.1.x
Align Manager’s Context Menu
• While the Align Manager is open the user can right mouse click on the Align
Manager’s Window to invoke the context menu.
• If Areas or Perimeters option are enabled, the user can also invoke the context
menu by CONTINUOUSLY right clicking on the graphics area.
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Casting v20.1.x
Direct
Fix result in Direct mode
The user can fix the result in Direct mode. Direct mode is
activated by clicking on the respective button on the Align
Manager window.
On the following table are all the actions that can be done in
direct mode. RMB and LMB are used.
RMB
Drag-drop RMB
LMB
Macro area
Collapse
Add to
Context Menu
Perimeter
Join
Add to
Context Menu
Hot point
Delete
Paste
-
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Casting v20.1.x
Direct
Fix macro areas with Direct
Direct actions available for Align Entities (macro
areas).
Drag and drop one Align entity to another one. Add to
will be executed
Click on the interior of the macro area. The macro area
will collapse.
! Note: While in Direct mode, left clicking on an entity
invokes the context menu.
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Casting v20.1.x
Direct
Fix perimeters with Direct
Direct actions available for Perimeters.
Drag and drop one perimeter to another one. Add to will
be executed.
Click on the interior of a perimeter. The perimeter will be
joined (with merge option).
! Note: While in Direct mode, left clicking on a perimeter
invokes the context menu.
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Casting v20.1.x
Direct
Fix hot points with Direct
Direct actions available for Hot Points.
Drag and drop a hot point to a grid. Paste will be
executed.
Click on a hot point. The hot point will be deleted.
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Casting v20.1.x
Observing The Result Generated By Casting
• If we observe the
result we notice that
some areas are not
as expected.
• These could be
empty areas, or areas
that got erroneous
association with
geometry.
• Fixing is done by
either correcting the
association or by
creating a new one.
Empty Areas!
Empty Areas!
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Casting v20.1.x
Observing The Result Generated By Casting
Wrong association!
CTRL+A
Missing Feature!
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Casting v20.1.x
Observing The Result Generated By Casting
Distorted thick area!
Missing thick area!
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Casting v20.1.x
Fix Empty Area
2
1
Pick the empty shells, use right
mouse click to invoke the context
menu and select the Add to function.
Select the Align entity to which the
empty shells will be added.
Confirm with middle mouse click.
The corner is fixed.
! Note: If the Align mesh after modifying Align rules options is NOT
checked, the corner will NOT automatically be Aligned and Align
command should be used.
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Casting v20.1.x
Fix Wrong Geometry Association
Enable Direct mode and
hover over the Align
Entity. Its geometrical
definition is wrong.
Drag and drop it to the correctly associated rib as
shown in the picture.
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Casting v20.1.x
Fix Feature With Different Geometry In Each Side
Make Corner
We notice than the one side of
the geometry is a planar face
and the other is a small fillet.
Keep Direct mode
enabled. Click and join
the Perimeter.
Drag and drop the macro
area to make a corner as
shown.
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Casting v20.1.x
Fix Feature With Different Geometry In Each Side
Define New Plane
While still in Direct mode, left click
on the macro area and invoke the
context menu. Select New>Plane.
Select 2 faces to define the middle
plane. A preview is shown in the
screen.
Confirm with middle mouse click.
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Casting v20.1.x
Create Missing Feature
We notice that this feature is totally lost and it should be
created manually.
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Casting v20.1.x
Create Missing Feature
Delete And Create New Elements
Use Elements>Delete.
Use Elements>New>New.
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Casting v20.1.x
Create Feature
Create Two Macro Areas
Use Elements>Split to divide
the one quad into two.
For this feature we need 2 different
Align entities, which means 2 different
macro areas.
Use Macros>Edje2perimeter
to create two macro areas.
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Casting v20.1.x
Create Missing Feature
Add To
Invoke the context menu,
select Add to and add the one
shell to the plane below.
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Casting v20.1.x
Create Missing Feature
New Offset
Invoke the context menu,
select New>Offset.
Select the new shells and press Next.
Pick the thickness from the screen.
Select the face that will be
used for offset.
The Align entity lies exactly in the
middle of the thickness.
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Casting v20.1.x
Create Missing Feature
Alignment Of Edges
Use Hot Points>Insert to split
the perimeters.
Use New>Perimeter to assign the
edges on the desired faces
Use New>Perimeter to assign the
edges on the desired faces
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Casting v20.1.x
Fix Thick Area (1/2)
Change Intersection Angle
In this case the intersection angle between the align entities
has to be changed.
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Casting v20.1.x
Fix Thick Area (1/2)
Fix the distortion of the junction
Enable Direct mode. Drag and drop
the Hot Point as shown.
Use Grids>Paste
to paste the
extra nodes as
shown.
2
1
2
1
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Casting v20.1.x
Fix Thick Area (1/2)
Change Intersection Angle
2
2
1
1
Select ALL Align
entities
participating in the
junction.
2
1 Set the Angle limit
to 5°.
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Casting v20.1.x
Fix Thick Area (2/2)
Create solid elements
In this case solid elements should be created in the thick area.
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Casting v20.1.x
Fix Thick Area (2/2)
Prepare bounds for the creation of solids
Use Faces>Cut to make the
desired bounds.
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Casting v20.1.x
Fix Thick Area (2/2)
Imprint bounds to the FE
Use Imprint to
project CONS on
the FE.
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Casting v20.1.x
Fix Thick Area (2/2)
Prepare bounds on the FE
Use Macros>Cut
to close the area
that will be filled
with solids.
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Casting v20.1.x
Fix Thick Area (2/2)
Prepare bounds on the FE
Delete wrong shells.
Use Merge to
unify the macro
area.
Use Hot
Points>Delete to
delete
unnecessary hot
points.
Use Reconstruct
to improve the
mesh.
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Casting v20.1.x
Fix Thick Area (2/2)
Create solid elements
Use Structured
Mesh>Solid
builder to create
Hexa and Penta
elements.
Enable Auto-Build option.
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Casting v20.1.x
Fix Thick Area (2/2)
Result
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Casting v20.1.x
Treat O-junctions (Auto)
Create solid elements
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Casting v20.1.x
Treat O-junctions (Auto)
Create solid elements
Use Mid.Surface>Ojunction>Auto.
Ojunctions are automatically
recognized and treated.
! Note: The elements are created based on the target element length of
global Mesh Parameters!
! Note: On the options list the user can select to create Shells/Solids. In
case of Solids, interface shells can be added.
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Casting v20.1.x
Treat O-junctions (Manual)
Create solid elements
Define the Top Axis cylinder point.
Define the Bottom
Axis cylinder point.
Specify the options for the
created elements.
Use Mid.Surface>Ojunction>Manual.
On this case the cylinder should be defined manually.
! Note: For the definition of axis points 3 point selection is available. Pick
3 points on the circle’s circumference and the center is auto-defined.
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Casting v20.1.x
Treat O-junctions (Manual)
Result
External interface shells where
added.
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Casting v20.1.x
Fix Feature After A Design Change
Plane Ribs Where Re-Designed As Round
! Note: With the use of Align Manager, we can very easily embrace design
changes.
For example, lets say that these plane ribs were re-designed as round ones.
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Casting v20.1.x
Fix Feature After A Design Change
Plane Ribs Where Re-Designed As Round
Pick the one rib, invoke
context menu and select
New>Middle.
Select the first and the
second group of faces.
Confirm with middle mouse
click.
Pick the other rib, invoke
context menu and select
New>Middle.
Select the first and the
second group of faces.
Confirm with middle mouse
click.
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Casting v20.1.x
Merge Align Entities
Fix Mesh Flow
Select the two Align entities and
invoke context menu. Select
Merge.
The two Align entities where
merged.
! Note: Merge can be used to combine 2 or more Align entities into
one and it can be used to fix the mesh flow.
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Casting v20.1.x
Macros Join
Merge Align Entities
Use Macros>Join as shown in the
picture.
The Align entities where merged.
! Note: Macros>Join merges the Align entities as long as Merge
options is selected at the Options List.
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Casting v20.1.x
Check shells’ thickness
• Go to the Presentation Parameters tab of the Quality
Criteria window (F11) and enable the Draw shell as
solid option.
• Now the shells appear as solids and it is easy to
visually check their thickness.
• Switch on the visibility of the geometry; there is a
perfect match!
! Note: Draw shell as solid option can also be enabled
from the Presentation Parameters toolbar. You can
activate the toolbar from
Windows>Toolbars>Presentation Parameters.
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Casting v20.1.x
Convert Nodal To Property Thickness
Apply Grids>Thickness>Convert, select the whole
model and confirm with middle mouse click.
Choose Nodal to Property, specify a Thickness
Step and press OK.
! Note: After applying Grids>Thickness>Convert nodal
thickness is set to 0.
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Casting v20.1.x
Extract Geometry Out Of FE
Select all Align Entities with Ctrl+A, invoke
context menu and use Actions>Convert to
Geometry.
Geometry was extracted out of the
FE.
! Note: On the options list the user can select to what
Property the new Faces will be assigned.
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Casting v20.1.x
Useful Advices
Tips And Tricks!
1. Every action is done with respect to global Mesh Parameters and Quality
Criteria. So after you run casting, be sure to have them set properly. They
are independent from the parameters that were used to run casting!
2. Sometimes it is better to run casting with a small Target Element Length,
and then Reconstruct the whole model with desired Mesh Parameters
and Quality Criteria. The result will be better and easier to fix.
3. Offset Align entity type can be very useful in cases where the geometry
in the two opposite sides is different.
4. Converting Nodal to Property thickness should be the last thing to do
AFTER fixing the result because Align command will recalculate nodal
thickness. If all Align manager options are checked, every Align
manager/Mesh action will Align and recalculate Nodal Thickness.
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