How Can Simulation Help Cast Products During the Development Cycle

Kunju noted that many of the trends worldwide solutions boil down to the search for lighter products.
“Light weight has become very critical in the future. Emissions regulations making this a critical part,” said Kunju. “More than 70 percent of steel metal used today, but fast forward 20 years from now, it will be less than 20 percent. Aluminum and magnesium will increase due to its lighter weight.”

The trend of light weight and non-ferrous metals used engineers are forced to explore radical design and manufacturing technologies. The aim of these technologies to reduce the chances late in the development cycle issues.

For example, can engineer for optimization topology part to Inspire solidThinking’s, evaluate castability in Click2Cast, assess the fatigue life of the part using DesignLife (available through the Alliance Partner Altair) and then prototype the traditional solutions, using 3D printed patterns and models. By iterating this process on the computer instead of the shop floor, engineers can create light-weight parts that are comparable or even better than the original at a lower cost.

“Add Inspire and Click2Cast up front and you can do all the design concept up front and reduce the current cycle,” said Kunju. “This will help to reduce costs. Inspire 3D optimization gives a lot of freedom. Click2Cast The manufacturing feasibility assessment.”

Using this strategy, the staff explained that racecar Kunju students able to use wheel upright. Although the ending up to be the same weight as the benchmark, the performance side was the 3-5 times more intense. The team also played a part were ready for mass production.

Using simulation, the team was able to learn a lot about how to manufacture the part in just a few hours. For example, information such as where to put the Ingate solutions, did not need a physical trial and error. They were able to determine the best sites to Ingate spend a minimum porosity.

Once the test was complete virtual, the team was able to 3D print the pattern for casting, and then he spent there. By applying this technique, engineers can improve the industry profit margins and their products.

Can also be useful to engineers Click2Cast end product development cycle. For example, engineers can determine the optimum positions and shape risers, inlets and vents limit porosity and cold shuts in the final product.

Using Click2Cast, engineers can look the part solidification. This will help to determine where one could develop cavities and pores.Risers used as a reservoir of liquid metal, which feed into the part declared that reduce pore development. The riser is then cut away the part when the whole thing solidified. Click2Cast helps design the risers.

Cold shuts can also appear when the flow of the metal folds back on itself liquid. This can also create cavities and weak points in part with liquid metal together at different temperatures. Click2Cast can help optimize the placement of ingates to reduce the formation of cold shuts.

As Click2Cast simulations uses two stages, it can be considered the displacement of air during as it is filled with molten metal. This will create more accurate results to evaluate territorial separation and air pockets. Click2Cast can then help determine the best placement of vents to reduce air pockets.

Click2Cast automatically indicate the size and location of the risers, inlets and vents. However, the engineer can then use their industry knowledge to improve these proposals if they wish. The platform will not create them for the engineer, the engineer is still in control.

“We use [Click2Cast] to quickly evaluate projections for porosity and other defects mentioned as part of our process,” said Stephen Fetsko, engineering analyst at Shiloh Industries. “As we enter the project into production, Click2Cast we use to help optimize the design and location of the gates and runners.”