ProCAST General Presentation 5

ProCAST General Presentation

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THE VIRTUAL TRY-0UT SPACE” COMPANY

Case Study 4

steel Investment Casting

_CRKEATE

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=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 Jaws “ee Ot Beg, *——- - ` ` ———- -

` 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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'~EST GR0UP Case Study - Steel Locking Jaws

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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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

www.esi-group.com

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THE VIRTUAL TRY-0UT SPACE” COMPANY

Case Study 5

steel Sand Casting

_CRKEATE

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_=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:

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.`>EST GR0UP Case Study - Steel Sand Casting Ns ae Arrow shows shrinkage location on front shroud Suy x X% Noo (7 V/2\ SR Đà 7 K0 My tp WP ee EH PK) Rees On X2 eA cu Ni + : bÓ oS ie BK Ki A M¿ K đà te ) ` Ta neat at ` } RS A Se os 25 ey : AI VÀ ee CÀ 7 we

Và eke ma ons = A ra VATE al

San tái Dos - 2, et ee: aot ly,

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"=1 €,00)0), Case Study - Steel Sand

Casting

Secondary shrinkage at

riser-hub connection

Not a major concern as defect would be visible

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Second iteration:

1 Chill size was increased

2 Riser diameter was increased

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Case Study - Steel Sand Casting LA za Ne ‘| is] II es

The larger chill has

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THE VIRTUAL TRY-0UT SPACE” COMPANY

Case Study 6

steel Sand Casting

_CRKEATE

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Peas) COU Pump Casting @® Material @ Casting: CF8M Stainless Steel @â Mold: Sand @đ Weight @® Clean Casting: 35 kg @® Problem:

® Improving yield by reducing pouring weight @® Reducing machining cost

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| Aa) GROUP Background

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

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

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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

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Se (GROUP Results THE VIRTUAL TRY-OUT SPACE” COMPANY

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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THE VIRTUAL TRY-0UT SPACE” COMPANY

Conclusion

_CRKEATE

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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

â Reliable and accurate

@đ 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 â â â â @đ đ

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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EST GROUP selected Casting References

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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

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~ESI GROUP selected Casting References

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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, Switzerland Customer Statements

“The simulation calculations carried out with

ProCAST in sand casting were an extremely valuable help in order to obtain a low-cost and fault free first cast of cylinder crankcases in spheroidal iron.” 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., France

“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