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Pialorsi Stampi: The innovation of the Polini electric motor guaranteed by high-performance die-casting with QuickCast and ProCast

QuickCast and ProCast are the predictive software tools used by Pialorsi Stampi in the creation of an electric motor for e-bikes for Polini Motori. The product and process simulations offered by both software tools made it possible to transform an ambitious and innovative project for the construction of aluminium supports to connect the electric motor to the bike frame into reality.
The aim of the project was to make two non-porous parts using an alloy with sufficient mechanical properties to withstand the stresses of off-road use.
The technical challenge during the production phase was to create the best conditions for the welding and subsequent heat treatment of the components.
QuickCast and ProCast software were used to simulate three different possible settings for the mould with a view to choosing the most functional solution. The results of the simulations were gradually analysed and the right adjustments made it possible to eliminate any flaws highlighted by the predictive programmes during the design phase, resulting in a functioning end product with all the specifications required by the customer.

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Shot Peening Modeling in DEFORM

SFTC recently took part in a research project to develop modeling methods for shot peening processes. A deliverable from this work was the new Shot Peening Template, which streamlines the setup and simulation of this complicated process.
Shot peening is a beneficial surface treatment used in a wide range of industries. It induces a compressive residual stress on the surface of a metal component via cold working. This is accomplished by firing spherical shot onto a part at high velocity. The resulting compressive stress state counteracts tensile stresses experienced during inservice operation. This can greatly increase a part’s fatigue resistance.

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Die Insert Redesign with DEFORM

DEFORM was used to simulate the forming of the hex-head flange screw blank.
The stresses during forming were subsequently used to predict the effort and deflection of the equipment components. To study the matrix effectively, it is necessary to include the interaction between the matrix and the keying. The original matrix consisted of a hard metal insert and jacket.
DEFORM was used to perform a subsequent matrix stress analysis at the stage where the highest load was observed.

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