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Tutorials
Tutorials show you how to use Simcenter STAR-CCM+ for various applications in a step-by-step format with recommendations for setup, initialization and steps of the solution process specific to the application. Macro and simulation files are available for download for a large proportion of cases.
Incompressible Flow
The tutorials in this set illustrate various Simcenter STAR-CCM+ features for incompressible fluid flows as well as porosity and solution recording
Polymer Melt Extrusion: Film Casting
In industry, film casting is a common process for producing thin polymeric films. Cast films are used for applications such as food and textile packaging, stretch wraps, or plastic bags. Simcenter STAR-CCM+ provides a combination of the Film Casting model and the Free Surface model that allows you to simulate that process and to investigate the impact of various parameters on the resulting film.
Selecting the Physics Models for Film Casting
In this tutorial the simulation is a steady-state free surface calculation where the reduction of the film width during casting extrusion, (the neck-in of the film), is modeled using an Arbitrary Lagrangian-Eulerian (ALE) method. The viscoelastic model is used to describe the rheology of the extruded material.

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Tutorials
Tutorials show you how to use Simcenter STAR-CCM+ for various applications in a step-by-step format with recommendations for setup, initialization and steps of the solution process specific to the application. Macro and simulation files are available for download for a large proportion of cases.
- Using Tutorial Macros and Files
  Macros, input files, and final simulation files for a range of tutorials are provided as an optional download package on the Support Center website. These macros and final simulation files are provided as an aid to the written tutorials, so that you can check your final results against the downloaded files, or against a simulation that is built and run using the macros.
- Introduction
  Welcome to the Simcenter STAR-CCM+ introductory tutorial. In this tutorial, you explore the important concepts and workflow. Complete this tutorial before attempting any others.
- Foundation Tutorials
  The foundation tutorials showcase the major features of Simcenter STAR-CCM+ in a series of short tutorials.
- Geometry
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for creating and working with parts and 3D-CAD.
- Mesh
  The tutorials in this set illustrate various STAR-CCM+ features for building CFD meshes.
- Incompressible Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for incompressible fluid flows as well as porosity and solution recording
  - Steady Flow: Lid-Driven Cavity Flow
    This tutorial demonstrates the performance of Simcenter STAR-CCM+ in solving a traditional square lid-driven cavity flow. The problem geometry consists of a two-dimensional 1 m² cavity. The cavity is covered by an impermeable wall that moves in the x-direction with constant velocity of 1 m/s. A stretched quadrilateral mesh with 6400 cells is used.
  - Steady Flow: Channel Flow with Multiple Meshes
    This tutorial describes a steady airflow simulation over an obstacle that is mounted at the bottom wall of a three-dimensional channel.
  - Steady Flow: Laminar and Turbulent Flow in an S-Bend
    This tutorial demonstrates the flow of an incompressible gas through an s-bend of constant diameter (2 cm), for both laminar and turbulent flow. The first part of the tutorial covers the laminar flow, with a Reynolds number (Re) of 500, and the second part covers the turbulent flow, Re = 50,000. The same pipe geometry is used in both cases.
  - Steady Flow: Backward Facing Step
    Steady flow over a backward facing step is a typical scenario to investigate the behaviour of reattaching flows. Understanding the behaviour of the flow is crucial for many applications such as designing heat exhangers, evalutating aerodynamic performance and improving flow control strategies.
  - Anisotropic Flow: Cyclone Separator
    The flow inside a cyclone separator is characterised by strong swirling motion and three-dimensional boundary layers. Properly accounting for these effects is a challenging problem for CFD simulations. This tutorial presents the initial step in setting up a coarse mesh cyclone flow simulation.
  - Porous Resistance: Isotropic Media
    This tutorial models flow through a catalyst geometry.
  - Porous Resistance: Orthotropic Media
    This tutorial solves the same problem as the Porous Resistance: Isotropic Media, except that the fluid in the porous region cannot flow in any direction other than the bulk flow (y-) direction.
  - Solution Recording and Playback: Vortex Shedding
    This tutorial demonstrates how to use the solution recording and playback module for capturing the results of transient phenomena.
  - Generalized Newtonian Fluid: Flow in a Static Mixer
    This tutorial demonstrates the process of setting up and analyzing the flow of a viscous fluid through a static mixer.
  - Viscoelastic Flow: Basic Extrusion
    This tutorial illustrates the extrusion of molten rubber through a die.
  - Material Calibration: Curve Fitting Non-Newtonian Model Parameters
    This tutorial illustrates the workflow for calibrating rheological model parameters from experimental rheological data through curve-fitting.
  - Polymer Melt Extrusion: Film Casting
    In industry, film casting is a common process for producing thin polymeric films. Cast films are used for applications such as food and textile packaging, stretch wraps, or plastic bags. Simcenter STAR-CCM+ provides a combination of the Film Casting model and the Free Surface model that allows you to simulate that process and to investigate the impact of various parameters on the resulting film.
    - Prerequisites
      The Polymer Melt Extrusion: Film Casting tutorial assumes that you are already familiar with certain techniques in Simcenter STAR-CCM+.
    - Defining Geometry and Process Parameters
      Within 3D-CAD, you create the geometry of the film in its undeformed state and then apply design parameters to its length and width. Thereafter, in the simulation setup, you create global parameters for use when defining process conditions at boundaries.
    - Creating the Initial Film Mesh
      In Simcenter STAR-CCM+, a two-dimensional mesh is required for simulations of film casting. The mesh that you create represents the initial undeformed state of the film. In the course of the simulation the mesh deforms as part of the solution.
    - Selecting the Physics Models for Film Casting
      In this tutorial the simulation is a steady-state free surface calculation where the reduction of the film width during casting extrusion, (the neck-in of the film), is modeled using an Arbitrary Lagrangian-Eulerian (ALE) method. The viscoelastic model is used to describe the rheology of the extruded material.
    - Specifying Material Properties and Viscoelastic Model Parameters
      The extended PomPom model uses five parameters to model the viscoelastic behavior of the polymer melt.
    - Setting the Film Boundary Conditions
      The film enters the computational domain with a die exit velocity of 0.0043 m/s. Upon entry, the film is 0.46 mm thick and has a temperature of 400 K.
    - Specifying the Film Heat Transfer
      The temperature distribution over the film has great influence on the film formation, that is, its thickness and width. To capture this distribution accurately, you take both convection and radiation into account. The film has a temperature of 400 K at the die exit; the environment and the chill roll have a temperature of 300 K.
    - Plotting the Film Width and Thickness
      You create an X-Y graph that plots the width of the film from the centerline, given by the Y-coordinate, over the extrusion direction coordinate X. Another graph plots the film thickness across the outlet, that is, along the chill roll.
    - Visualizing Film Thickness, Temperature, and Velocity
      The film thickness is a solution variable and you can visualize its spatial distribution in the form of a scalar contour plot. Also of interest are the temperature and the velocity distribution of the extruded film. You display the velocity as a line integral convolution plot.
    - Running the Simulation
      You run the film casting simulation in steady-state until the relative change in residuals is less than 10^-8.
    - Analyzing the Results
      You can follow the progress of the solution using each of scenes that you created previously.
- Compressible Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for compressible fluid flows as well as harmonic balance.
- Heat Transfer and Radiation
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for heat transfer, radiation, and thermal comfort.
- Multiphase Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating multiphase fluid flow problems
- Discrete Element Method
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating Discrete Element Method problems
- Motion
  The tutorials in this set illustrate various STAR-CCM+ features for simulating problems with moving geometries and meshes, dynamic fluid body interaction, and rigid body motion:
- Reacting Flow
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for simulating reacting flows such as combustion.
- Solid Stress
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for computing deformation, strain, and stresses in solid regions. They also show how such computations can be coupled to the fluid behavior in an analysis of fluid-structure interaction.
- Aeroacoustics
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for solving aeroacoustic simulations.
- Electromagnetism
  The following tutorials illustrate features for solving problems that involve electromagnetic fields.
- Electrochemistry
  The following tutorial demonstrates chemical reactions induced by an electrical current.
- Battery
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for setting up a battery model:
- Automation
  The tutorials in this set illustrate various Simcenter STAR-CCM+ automation and macro features.
- Design Exploration
  The tutorials in this set illustrate various features for running design exploration studies in Design Manager.
- Coupling with CAE Codes
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for coupling with CAE codes:
- Analysis Methods
  The tutorials in this set illustrate various Simcenter STAR-CCM+ features for analysing and visualizing simulation data.
- Simcenter STAR-CCM+ In-cylinder
  The tutorials in this set illustrate features for simulating internal combustion engines in Simcenter STAR-CCM+ using the dedicated add-on Simcenter STAR-CCM+ In-cylinder.

Selecting the Physics Models for Film Casting

In this tutorial the simulation is a steady-state free surface calculation where the reduction of the film width during casting extrusion, (the neck-in of the film), is modeled using an Arbitrary Lagrangian-Eulerian (ALE) method. The viscoelastic model is used to describe the rheology of the extruded material.

The BSpline mesh morpher is activated in order to deform the mesh according to the free surface solution. The Film Casting model computes the film thickness. Radiation and convection heat transfer affect the formation of the film and are therefore accounted for in the simulation.

To select the physics models for film casting:

For the physics continuum, Continua > Physics 1, select the following models in order:


Group Box	Model
Enabled Models	Two Dimensional (Selected automatically)
Time	Steady
Material	Liquid
Flow	Viscous Flow
	Constant Density (selected automatically)
	Laminar (selected automatically)
Rheology	Viscoelastic
Optional Models	Film Casting
	Free Surface (selected automatically)
	Viscous Energy
	Viscous Radiation

Click Close.
To specify the extrusion direction, select Models > Free Surface and set Extrusion Direction to X.
Select the Tools > Motions > Morphing node and set Morpher Method to BSpline.
Save the simulation.