Running simulations during early development phase help to improve the efficiency, quality and cost-effectiveness of the production process by identifying and eliminating potential problems in advance.
1. Optimization of part design
Not all first designs are castable . Feasibility and part design optimization in terms of properties are possible with the help of simulations avoiding unnecessary material accumulation, thus avoiding errors and reducing costs.
Gate location uses to be a headache for producers , if the part designs doesn’t considers this from the beginning then problems will appear in the future.
2. Raw Material selection
Different alloys can be simulated to make the best choice for the specific requirements of the part. Each material flows and solidifies in a different way and this must be considered.
Filling performance and solidification behavior can be carried out even without an existing gating or venting system in order to derive important findings for component development.
3. Process optimization
Runners , overflow and venting system performance is defined and optimized before tool construction and when the tool goes to production we have a clear image of right parameters to get successful first samples. This is the key for project timing compliance.
In the example, various options for gate positions were tested and thanks to simulation software we could check and choose the best one.
4. Tool life guarantee
Cooling rates can be optimized to avoid stresses and cracks in the casting.
Hot spots can be prevented by special cooling means or even alternative materials or steel surface protection.
5. Quality performance
Defect avoidance: potential casting defects such as shrinkage, air entrapment and cold flow can be identified and avoided prior to production checking at simulation results key factors as:
- Total % of entrained air.
- Solid fraction during filling process
- Temperature of material at last points of filling
- Material speed at gates and critical areas.
- Cold spots.
6. Sustainability
Optimizing design and process, material and energy consumption can be reduced, leading to more sustainable production reducing carbon footprint of the product.
Conclusions
If you are involved on product design and have questions related to casting process simulations can help and solve most of them during the early stage of development.
Contact your casting partner in advance to avoid losing time in the future. At Grupo Geispen we have the means and work on it everyday to support our customers.
