Metal Casting Technologies : MCT MAR 2018 (1ST QRT)
38 www.metals.rala.com.au METAL Casting Technologies 1st Quarter 2018 39 ASIA PACIFIC CASTING TECHNOLOGIES A–F F–K M–Z ajaxtocco.com ajaxtocco.com amelt.com amelt.com beckwithmacbro.com.au beckwithmacbro.com.au coolfog.com.au coolfog.com.au didion.com didion.com magmasoft.com.sg magmasoft.com.sg flow3d.com flow3d.com minductiontech.com minductiontech.com foundry-eqpt.com foundry-eqpt.com objective3d.com.au objective3d.com.au hayesmetals.co.nz hayesmetals.co.nz spectrosource.com.au spectrosource.com.au inductotherm.com.au inductotherm.com.au voxeljet.com voxeljet.com kuka.com kuka.com altair.com altair.com australianfoundryinstitute.com.au australianfoundryinstitute.com.au castingtechnologynz.org castingtechnologynz.org dickinsons.com.au dickinsons.com.au finitesolutions.com finitesolutions.com foseco.com foseco.com metalsonline.rala.com.au metalsonline.rala.com.au foundrychina-gz.com foundrychina-gz.com mm-china.com mm-china.com glucinaalloys.co.nz glucinaalloys.co.nz spectro.com/lab spectro.com/lab hitachi-hightech.com/hha hitachi-hightech.com/hha thermofisher.com/oes thermofisher.com/oes keech3d.com.au keech3d.com.au wesomega.com.au wesomega.com.au WEB SHOWCASE Company Directory/Suppliers WEB SHOWCASE | COMPANY DIRECTORY/SUPPLIERS BacktoBASICS metal chemistry and temperature as well as mould type, the dimensions of a riser for each area can be determined. The system is also capable of determining gating requirements based on determination of an optimum fill time for the casting in question. Figure 5 shows the determination of optimum fill time based on 4 castings per mould. Using this information, the suggested risers and gating is added to the casting model and a verification simulation run. This is an important step, as it must be realised that the riser size calculations are approximations and cannot take into account all of the complex thermal interactions which occur in a fully-rigged casting. The fully rigged casting assembly is shown in Figure 6, and the simulation results, are as shown in Figures 7, 8 and 9. The macro-porosity prediction (the yellow area in Figure 9) shows clearly that the volume provided by the risers was sufficient to feed the casting without formation of internal shrinkage porosity in the castings. Conclusion Thus, within a time span of just a few minutes it was possible in this case to fully design adequate risering for this casting, given a CAD file transmitted from the customer. The user’s effort to perform these calculations is minimal, primarily just clicking on a few menu items and buttons on the screen. There are a number of issues in confluence today which make such an approach critical for a foundry to consider. First is the requirement by customers for shorter lead times as well as pressure to reduce cost and casting prices, meaning that getting the casting process designed correctly and quickly is imperative. Second is the wide availability today of 3D CAD models for most new castings. Third, and not the least in importance, is the fact that many experienced foundry engineers are nearing retirement age, and they are being replaced by younger people without the years of experience needed to develop a “feel” for the casting design process. Providing an automation tool to these younger engineers can dramatically increase their productivity in designing casting processes. n FIGURE 8. Solidification simulation. FIGURE 9. “X-Ray” plot of macro-porosity. FIGURE 7. Mould filling showing temperature distribution. ... WITHIN A TIME SPAN OF JUST A FEW MINUTES IT WAS POSSIBLE IN THIS CASE TO FULLY DESIGN ADEQUATE RISERING FOR THIS CASTING, GIVEN A CAD FILE TRANSMITTED FROM THE CUSTOMER.
MCT DEC 2017 (4TH QRT)
MCT JUN 2018 (2ND QRT)