Error creating new process when Analyzed

venomousDNA

when i tried to run my casting simulation i get this message and i have checked my ram availability and other satisfactory requirements too. I have also not set my run directory to a shared drive or virtual one, but i have not yet done my reinstallations.

what would it be the problem

trial-5-2-prt.prt.icast

i have attached my file above.

MilanRaval

Hello,

I just tested that the model is working fine in Inspire Cast 25. If you are using older version, I suggest to use latest. Also, I noticed that the gravity direction in your setup is incorrect.

venomousDNA

So even now after i try to simulate it in inspire cast 2025, i doesnt give me error creating new process

but now i see a new message of error which shows

so what show i do now as this model that i have used now has been tested in both the versions of the inspire cast 24 and 25

24 says error creating new process
25 says meshing error

so please help me find answer for this issue as I'm unable to do anything with this simulation software. I hope to get good answers from the community. THANK YOU

venomousDNA

i have used this model
The 3d model file that i have uploaded will be having an Un connectivity between the ingates and the cast part but have cleared it in the simulation software and then i when i chose to run this happened for solidification analysis.

altair-test.prt.icast

TEST.igs

MilanRaval

Hello @venomousDNA ,

I have figured out the cause of mesh failure. It was related to the way runner system was connected to the part. I have fixed it and now it has started computing the simulation. I have also attached the fixed CAD here. Please use this and it will work fine.

altair-test.prt.x_b

venomousDNA

Thanks much! May I know how you identified the error? What are the changes that has been made?

MilanRaval

Yes. if you look at your model closely, cast part and runner is connected by 3 small entinties. Not sure how you created them. As they are separate thin bodies, mesh creation was difficult as you are trying to create with large element size. I combined those bodies with runner using Boolean.

venomousDNA

Hi @MilanRaval

Understood. I had issues with Un connectivity, so I used Boolean modifier to fix the three gating issues you mentioned, but even then, I'm getting mesh creation error. Also, now when I tried running your file, I'm getting error: Error creating new process and also the mesh error occasionally