This thesis work has the purpose of providing a methodology of comparison between two different casting technologies, for the realization of a hub holder of a car suspension unit, both from the point of view of the mechanical characteristics of the piece obtained, and from the economic point of view, through:
1) analysis of the industrialization of the upright holder obtained by gravity casting;
2) the formulation of hypotheses to adapt the piece to the design constraints of low pressure technology, resulting in the performance of casting tests using a casting simulation software.
Case study of a motorcycle swingarm produced by the Fonderia Scacchetti Leghe Leggere. It is important that the designer is aware of the residual stresses present in each area of the component. Article in Italian
Read More”Before the introduction of ESI ProCAST, the percentage of defects was relatively high, leading to a smaller yield. It was impossible to accept this with an increase in production and the diversification of products. We were able to reduce the percentage of defects to a very large extent thanks to a high accuracy simulation tool like ProCAST.”
Mr. Katsuhiko Ashida
Chief Engineer, Development Operations
Nissin Kogyo Co. Ltd
In the Department of Mechanical and Industrial Engineering of the University of Brescia, in collaboration with the OMR companies (Officine Meccaniche Rezzatesi) and FMB the foundry of the group, a research has recently been carried out, part of the project called “2 mm”, related to the effects of the exposition in temperature on components made in thermal treated aluminum alloy for the automotive sector ...
Read MoreProCAST a FEM simulation based virtual casting environment for analysis of casting process is used as a tool for die design and process optimization.
ProCAST, QuikCAST and QuikCAST Light simulation software help the designer visualize metal flow in the die cavity, temperature changes, solidification progress and the evolution of defects such as shrinkage porosity, cold shrinkage, cracking hot and so on.
PROJECT MIUR “2mm” (Part 1 of 2) – Project Goal
Weight reduction and mechanical properties increase for automotive structural components cast in light metal alloy in Gravity Die Casting and LPDC.
Aim of the project is to produce automotive structural components for space frame with
thickness reduced from 4 to 2mm by the use of innovative low pressure and gravity die
casting plants and dies with vacuum, real time monitoring and closed loop logic
management. Research and tuning of an optimal aluminum alloy suitable both for gravity
die casting and LPDC.
Casting simulations will define alloy composition, component
design, gating and evacuation system, heating die, process parameters and best fitting
equipment.
BENEFITS
. To trade in empiricism for a more
accurate numerical approach of
the casting process;
. Better knowledge and control of
the casting alloy and process;
. Higher quality of the cast bell;
. Early design for manufacturing
Benefits
Using ESI QuikCAST, part of ESI’s casting solution, Renault was able to enhance competitiveness, reduce development time and cost and improve product quality. Most importantly they increased their know-how of filling and feeding systems for casting and established new production design methodology.
Ausferritic ductile iron (ADI) combines the freedom of the molding style of cast iron with the strengths of steel. ADI forms by heat treatment of nodular cast iron. To take full advantage of the technical potential of this material, extensive controls of the casting and the heat treatment processes are required. The authors describe an integrated approach of experimental studies and modelling for optimum process design. The simulation tools developed permit exact predictions of the microstructure due to the heat treatment. If certain suitable technical parameters are observed, an ausferritic microstructure without pearlite, martensite and bainite can be obtained. The parts produced had very good reproducible mechanical properties distinctly better than the applicable limits
Read MoreBenefits:
Foundry:
. Suppression/reduction of physical trials
. Reduction of recovering and rejecting causes
. Enhanced understanding of process capability
. Casting/process optimization
. Better fit with customer requirements
Customer:
. Effective and early design for manufacturing
THE BENEFIT
. Deliver realistic predictions at each step of the casting process
. Optimize the filling and solidification phases
. Minimize thickness and weight of the part
. Improve metallurgical quality
Choosing QuikCAST, a comprehensive physics-based software package to perform casting of a new brake calliper, the Azterlan research institute achieved the goal to improve the metallurgical quality without modifying the part geometry. The part was manufactured with spheroidal cast iron, of GGG50-7 quality, using a vertical molding machine that produces 300 molds per hour.
Fonderia Casati based in Varese, specialised in the production of exhaust manifolds and of turbines for European and Eastern market, invested a lot in casting simulation. In fact, they bought simulator ProCAST, complete with advanced module of stress and of portable module ViewCAST. Thanks to this module of stress, besides the traditional filling and solidification, it is possible to preview the deformations that the manifold is subjected to during the solidification and cooling, to measure, in a precise way, the deviations and to verify that the dimensions comply with the required specifications.
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