CAST-DESIGNER: A New Approach towards Casting Production Optimization

【ABSTRACT】In Casting, the rate of production and the quality of the parts produced in mass production process depends on cycle time. The cycle time of a part can be reduced by reducing the cooling time. The cooling time can be achieved by the uniform temperature distribution in the moulded part which helps in quick dissipation of heat. At the same time, the mould temperature should be maintained a uniform distribution to minimum the part warping and extend the die life time. This paper describes the analytical study of the mould cycling optimization and the cooling channel control during the mass production, a new casting production optimization method has been introduced.

CAST-DESIGNER: THE ALL IN ONE SOLUTION FOR CASTING BUSINESS, FROM PART DESIGN, TO MANUFACTURING, TO PERFORMANCE VALIDATION

【ABSTRACT】As the development of technologies, numerical simulation and digital technologies bring advantage to casting business, such as the DFM, casting system design and thermal/flow/stress/microstructure whole physical field simulation, this bring benefits to quality improvement and cost saving. Now, the latest Cast-Designer software can help the user to validate the casting performance directly, the casting defects could be validated in the performance software directly, such as the shrinkage porosity, gas porosity and residual stress.

DEVELOPMENT AND APPLICATION OF CASTING DISTORTION & COMPENSATION TECHNOLOGY BASED ON AUTOMATIC ITERATION METHOD

【ABSTRACT】Casting warp or distortion is one of the main defects often encountered in the production of die-casting, it is also quite difficult to solve. The traditional methods have the problems of low efficiency, heavy workload and poor working environment. This paper introduced Cast-Designer's newly developed distortion compensation solver DCS (Distortion Compensation Solver), it can predict the casting distortion and warp in advance and find the casting products meet the tolerance requirements in the automatic iterative optimization technology. With such tools and technology, we can reduce the casting distortion effectively and meet the machining requirements directly.

Automatic Optimization Technology Solve the Problem of Gas Porosity in Complex Casting Parts

【ABSTRACT】Automatic optimization of artificial intelligence is a hot topic today. However, how to apply such technology to general industrial enterprises application is more interesting. This paper introduces the application of artificial intelligence techniques in the gating system design of high pressure die casting, make it fully automatic optimization, detailing its basic principle, application methods and techniques.

Gas Bubble Tracking During Casting Filling Process

【ABSTRACT】During numerical simulation, one of the biggest challenges is to simulate the smallest air bubbles that can be entrained in the metal. In fact, in common fluid-dynamic simulation of casting process filling each time a region of air gets smaller than the element size it disappears, losing all the information about its presence and the possible defects that this implies. If the engineers with enough experience and good background, who can track the regions of air entrapped during the filling process and check manually where they, especially the last ones, close up and disappear. However, this approach is too approximated and does not keep in account the final movement displacement of the bubble.