ProCAST General Presentation 5

ProCAST General Presentation

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Case Study 4

steel Investment Casting

_CRKEATE

=EST GROUP, Case Study - Steel Locking Jaws

@ Gas and shrinkage porosity were observed in

the initial design of the cast freight trailer

component

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THE VIRTUAL T#Y-OUT S%PACEF* COMPANY ESI GROUP Case Study - Steel Locking

ϬvAzr=¬

Mesh

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ESI GROUP Case Study - Steel Locking

` The air cannot escape

from the lower castings,

» \ because the upper ones

are filling too early

X _ Vy

'Eltlucnarune Animated image

STEP NUMBER = 132

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This filling problem due to an ineffic

tree design leads to entrapped air

in the casting

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_'<ESĨ GROUP Case Study - Steel Locking

Jaws

Solidification contour plot

VIE PRACTION SOLID

STEP NUMBER = 279 Animated image

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_=ESI GROUP Case Study - Steel Locking Jaws

Macroporosity (shrinkage porosity)

contour plot

SIEP NUMBER = 849 www.esi-group.com

ake Nou: Case Study - Steel Locking

Jaws

Change in process design, in order to avoid entrapped air and reduce shrinkage porosity

At EMPERATURE

STEP NUMBER = 140 | Animated image

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ESI GROUP Conclusion

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@® Selected customers in investment casting, mainly in the aerospace

industry: A/stom, PCC Airfoils, PCC Structural, Howmet, Snecma, FHolls Royce, EMA, Doncasters, Microfusione Stellite, Centro Sviluppo Material, Microcast, Microsteel, Precicast, AIDC, Bet Semesh,

Stryker Howmedica, MFL, GE, Pratt-Wittney, Mitsubishi, [shikawajima Precision Casting, Starmet, Cercast, SALUT, Harbin Donkan Engine, Shenyang Liming Aero-Engine Group, Xi'an Aero Engine company

"For several years, ProCAST has been used at Howmet for customer concurrent engineering, development of new components and optimization of our investment casting processes ProCAST allows us to quickly optimize our gating systems in terms of filling and solidification Simulation results are then stored in a technical database used by our product and process development department."

Loic CALBA, CAD & Process Modelling Manager, Howmet S.A.S., France

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Case Study 5

steel Sand Casting

_CRKEATE

_=ESI GROUP Case Study - Steel Sand Casting

@® Production problem solved with casting simulation

@® Primary & secondary shrink porosity in critical areas

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| Ses GROUP Case Study - Steel Sand

Casting

First iteration:

Initial design modification

of back shroud section (top view)

This concession allowed

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San tái Dos - 2, et ee: aot ly,

và” a eae \ ĐẠI vi “ ee hài

sacs vase Study - steel Sand Casting

ch t3

Hy

v ` sea

Then solidification progressing from casting to risers

_=ESI GROUP TLL Case Study - Steel Sand Casting

The macroporosity plot shows shrinkage defects

at each shroud-vane junctions

"=1 €,00)0), Case Study - Steel Sand

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Second iteration:

1 Chill size was increased

2 Riser diameter was increased

Copyright © ESI Group 2007 All rights reserved

Case Study - Steel Sand

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Case Study 6

steel Sand Casting

_CRKEATE

Peas) COU Pump Casting

® Improving yield by reducing pouring weight

@® Reducing machining cost

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The example casting was part of a large transfer of patterns from another

foundry These patterns came fully risered and gated Although the existing

riggings yielded sound castings, it was felt that the there was opportunity for cost reductions by yield improvements and cleaning time reductions

Original

design:

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ESI GROUP Procedure

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The solidification of castings without risers was done first to determine critical thermal regions and placement of risers Simulations with risers was done next For expediency reasons Fluid Flow analysis and Modeling of Feeding aids was not done as they were considered unnecessary for the type of information we were after

Initial iteration (no risers):

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THE VIRTUAL TRY-OUT SPACE” ESI GROUP COMPANY First iteration with 4 risers

This riser has caused shrinkage

to appear in the discharge flange

lên - GROUP ine A138 115 d4 II Shel sas New Set-Up with 5 risers

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THE VIRTUAL TRY-OUT SPACE” ESTI GR0UP COMPANY Second Iteration with 5 risers

This iteration shows a sound casting

Porosity in this region was eliminated by adding a chill

In this example two iterations

with risers were done

Number of risers was reduced from 9 to 5, pouring weight was reduced by 15 kg per casting and cut off and grinding surface was significantly reduced

Validation with Radiography proved castings to be sound

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Conclusion

_CRKEATE

ESI GROUP icone Why Simulation is needed for Cast ng ?

® Shorten Lead time for part develooment

® Manufacturing Process Optimisation

® _ Quality Improvement — less scrap

@ Marketing Purpose

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THE VIRTUAL TRY-OUT SPACE” ESI GROUP COMPANY Why ESI GROUP Casting solution 2

@® Recognized as Global Leader in Manufacturing Process Analysis

® Expert in metallurgy / Participation in many European and International projects since 1986

® Knowledge of two technologies FDM and FEM

© Reliable and accurate

@® Material properties are easily accessible or computed,

@® Unique capability in |nvestment casting, Sand Casting, HPDC due to ability in modeling the

complete process:

© Shell cooling phase

Automatic shell generator with high accuracy Radiation effect accurately modeled

3D Shot sleeve modeling with vacuum and air entrapment modeling

Solidification with macro/ micro/ gas-shrinkage prediction Stress analysis for hot tearing, cracking, die life and part/ die distortions predictions

Advanced metallurgical modules such as CAFE and Microstructure modeling

© Very fast Parallel Version available

® Upgraded versions are regularly released

© Efficient worldwide customer support with local presence

@ Prestigious Casting reference list WW Presence in all continents

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Material supplier

@® Alcoa, Alcan, Corus, Umicore, Kawasaki steel, Mitsubishi, Hydro, Novelis, Bao Steel, Bohler.,

Mould and die designer

@© MCS, Costamp, Bieffe, American Tool & Mould, Ehlert Tools, SPARTAN,

Foundries

@ PCC, Howmet, Grey Syracuse, Chrome Alloy, Gould Pumps, Citation, Amcast, Georg Fischer, Neimeng No 1 Machinery Group (Baotou) Co., Ltd, Fagor Ederlan, Enkei, Daisin, Hong Fu Jin Precision Industry (TaiYuan) Co.,Ltd., Yuanging Aluminium wheel, ANJI FOUNDRY

WORKS, Dalian Heavy Industries Steel Casting Co.,Ltd, Guangzhou Seagull

Part owner

® Mazda, GM, DCX, Hyundai, Yamaha Motor, Honda, Aishin, Michelin, Chrysler, PSA, Renault,

Integrated company (design/casting)

@ RR, EMA, SNECMA, MAN, GE, P&W, Black & Decker, KWC, Canon, Denso, SALUT, Harbin

Donkan Engine, SHENYANG LIMING AERO-ENGINE Group, Xi'an Aero Engine company

R&D & Universities

@ NASA, Fraunhofer, CSM, Inasmet, ORNL, Tokyo Uni., CNRC, Centre de Haute Technologie, CTI, CTIF, Hong Kong Polytechnic University, SICHUAN UNIVERSITY, SHANXI VEHICLE

ENGINE INSTITUTE, Shanghai University, Beijing University

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“With ProCAST we got an efficient tool for checking

and optimizing what our mold designers could only

assume in the past With our first simulation we

were able to correct successfully the gating system

of a problematic HPDC tool for an aluminum casting

in an impressive way.” JOrg Lagemann, Engineering

Manager, Alu Menziken Injecta Druckguss AG,

Thomas Schuszter, Manager Process Engineering and Pattern Shop, MAN B&W Diesel AG, Germany

“For several years, ProCAST has been used at Howmet for customer concurrent engineering, development of new components and optimization

of our investment casting processes ProCAST allows

us to quickly optimize our gating systems in terms of filling and solidification Simulation results are then stored in a technical database used by our product and process development department.” Loic Calba, CAD & Process Modeling Manager, Howmet S.A.S.,

“To estimate the interfacial heat transfer coefficients,

we conducted low pressure die casting and squeeze

casting experiments The measured cooling curves

from thermocouple locations in the die and cavity

agreed well with the ProCAST results.”

Bob Pehike, Professor, Dept of Materials Science &

Engineering, University of Michigan, USA

“ProCAST is an extraordinary software when it comes to complex thin walled components.” Stefan Gustafsson Ledell, Technical Coordinator Casting Design, Swedish Foundry Association, Sweden

metallurgical quality for all manufactured

components while reducing development times

industrial requirements” Marcello Boschini,

Brembo, Italy

“We produce safety components for the automotive

“All new castings are simulated with ProCAST before the first trials The number of faulty castings was

reduced since then.” Stefan Nelle, Research and

Development Engineer, Walzengiesserei Coswig GmbH, Germany

industry It is therefore essential for us to guarantee

Since 1995, ProCAST has helped us meet these

“ProCAST has been implemented in our company for

a number of years Its usage has demonstrated to be valuable in the design of dies for our low pressure die casting machines.” Michael Bader, Technical Manager, KWC AG Engineering, Switzerland

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THE VIRTUAL TRY-OUT SPACE” COMPANY ESI GROUP The Open VTOS in Action

& Plastics Welding

& Heat Treatment

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