Welcome to part five of our Altair Inspire Cast blog series. In this eight-part series, we share tips, tricks, and address common issues and questions when getting started with Inspire Cast. In this quick tip, you’ll learn about Component Mesh Factors.
Have you ever received the “element size is very small” error in Inspire cast?
Chances are good that the answer is yes. This error is especially common when working with large, intricate, and/or complex castings. This message is a warning that generates when the predicted mesh element size is over 1 million elements.
You’ll still be able to run a simulation, but it’ll take a very long time. Fortunately, there are some ways to reduce the overall mesh size while still maintaining simulation best practices. This can be achieved with Component Mesh Factors.
On the Run Analysis menu, there are two tabs: Stages and Advanced. Selecting the Advanced tab will bring you to the Component Mesh Factors.
The Component Mesh Factors allow you to manipulate the element sizes of individual components based on the element size of the main part. For example, if you had a 2 mm element size for your part and set the Component Mesh Factor of the Runner to 1.5, this would make the element size of the Runner 1.5 times larger than the part, or 3 mm. This is particularly advantageous when running intricate parts, as you can reduce the complexity of secondary mold components to speed up solve times.
Caution: You should refrain from manipulating the Gate and Mold mesh factors if possible. The Gate needs to be a little more refined than surrounding areas to ensure a quality mesh there and the Mold is auto-generated based on the size of the casting.
If you are comfortable with this tool, feel free to play around with any of the values. Component Mesh Factors, when used appropriately, can greatly reduce your solve times in Inspire Cast.
In the next blog in our series, we discuss diagnosing porosity problems. Take a look .
About Drew Tucker
Drew Tucker is an Application Engineer for Manufacturing Solutions at Altair. He is the lead for Altair's explicit manufacturing simulation solutions in the Americas, and is heavily involved in metal casting & prototyping. Drew is a graduate from Western Michigan University's Engineering College and has over 10 years experience in manufacturing sector. Drew is focused on bridging the gap between additive and traditional manufacturing technologies specifically, through the use of simulation software.
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