by clicking the arrows at the side of the page, or by using the toolbar.
by clicking anywhere on the page.
by dragging the page around when zoomed in.
by clicking anywhere on the page when zoomed in.
web sites or send emails by clicking on hyperlinks.
Email this page to a friend
Search this issue
Index - jump to page or section
Archive - view past issues
button in toolbar for more information.
Metal Casting Technologies : March 2009
TECHNOLOGY FEATURE Automobiles NewWorldOF THE reduced workers’ compensation due to occupational diseases. Cost sensitive engineering is a strategy that means improving casting quality, reducing casting development times, and reducing cost. 3) Research and development technologies are needed to facilitate a system improvement. New alloys to improve strength-to-weight ratio and new processes that seek a greener path to casted shapes are needed. The industry needs clean reliable energy at a fair cost. Non-traditional rapid casting techniques need to be incorporated which will shorten development times and produce net- shaped thin wall castings. 4) The trial-and-error practice in gating design must be stopped. Rather, employing computer-aided engineering (CAE) going from flow and solidification simulation to finite element analysis (FEA)should be used for design optimization. Furthermore, expert systems are needed for material selection, defect recognition and cause identification. In addition, linking computer aided design (CAD) models to thermal analysis for gating designs can bring us closer to virtual reality and eventually to sound castings. Digital manufacturing allows tooling data to be transferred from CAD to CAE to computer aided manufacturing CAM 5) Simultaneous engineering helps to reduce lead times, but even greater gains can be made through computer integrated manufacturing (CIM). Digital manufacturing allows tooling data to be transferred from CAD to CAE to computer-aided manufacturing (CAM). Further, employing the mega trends of just in time (JIT), kanban, design for manufacturing (DFM), and automation must all be applied to achieve an agile metal casting industry. In tougher economic times with high energy cost and no ease on regulations the government cannot save our industry. However, new markets and superior technology can be the solution. Fortunately, interest in engineering education in the metal casting field remains strong as aspiring engineers easily identify with the versatility and magic of the process. BIOGRAPHY Dr. Sam Ramrattan is a Full Professor in the Department of Industrial & Manufacturing Engineering, College of Engineering and Applied Sciences, Western Michigan University. He received his Bachelors & Masters from the University of Wisconsin-Stout, and Ph.D. & Post Doc. from Iowa State University. His area of specialization is materials & processes emphasizing casting processes. He is a senior member of the Society of Plastics Engineers and the Society of Manufacturing Engineers. He is a member of two research committees at the American Foundry Society (AFS), Technical Advisor to the Western Michigan University Student Chapter AFS, a member of the North American Die Casting Association (NADCA), and a Key Professor for the Foundry Educational Foundation (FEF). He is a member of two national honour societies TAP and EPT and has been awarded patents. He has published more than one hundred and twenty technical papers and has given technical presentations in eight different countries. Sam has taught at the University of Wisconsin-Stout, Iowa State University, and University of Technology Malaysia. His research projects includes casting issues at the mold/metal interface; alternative foundry molding media; full scale functional rapid prototyping; refractory coating control, and the development of foundry sand testing equipment. He regularly runs manufacturing related short courses for industry. 32 www.metals.rala.com.au