27/12/2021
Success stories
. Ever-enhanced safety: simulate
completely and accurately large
nuclear components
. Optimal quality and applicability
of simulation for leaders in nuclear
power
. Hardware solutions with the most
computational power ever on
the market at affordable cost of
ownership
. Precise and efficient dimensioning
analyses and behavior simulations
27/12/2021
Success stories
Using ESI QuikCAST virtual casting solution, Epcor was ableto evaluate alternative die designs at a fraction of the standard development time and cost to deliver higher quality parts to their customer, and be faster than the competition. They successfully achieved a 98% first time through put for the initial parts.
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27/12/2021
Success stories
Sand Casting – Aluminium Helicopter Transmission Case Filling - Solidification - Stresses - Deformations
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27/12/2021
Success stories
1. The Italia castings are characterized by very high quality and have extreme supply specifications 2. The time available is minimal and it is not allowed to make a mistake in the merger 3. It is possible to meet these requirements, with these times and minimize costs by giving the great experience and knowledge of the Foundry the Virtual Sampling of the casting simulation software. Excellent alignment “ProCAST Software Results” with “Reality” 4. Co design and definition of the casting system and uprights guided by the simulation of casting on the piece alone Article in Italian
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27/12/2021
Success stories
THE BENEFITS:
Validate the manufacturing tool of a foundry component and successfully move to production
Investigate the feasibility of a difficult thin-walled component while ensuring in-service performance of the product
Cost savings for tool development and production Allow decision-making early in the design phase
27/12/2021
Success stories
THE BENEFITS:
• The component wall thickness was reduced from 6mm to 3.5mm
• Casting weight was reduced significantly.
• 30% reduction in the total production cost
"During this project we used ProCAST software and that gave us the possibility to simulate & optimize thin-walled steel castings. ProCAST is a very competent software, when it comes to simulate thinwalled geometries"
Per Ytterell,
Managing Director (participant in the project, supplier of this steel component),
Smålands Stålgjuteri AB, Sweden
27/12/2021
Success stories
“The objective of DSB EURO is to satisfy
the requirements of our customers
regarding the quality of our products at
the highest level.
ProCAST helps us not only to enhance
the quality of our castings but also to
ensure a better competitiveness. Using
ProCAST enables us to deliver castings
on time and to cut back unnecessary
and repeated rework operations.
Finally, thanks to ProCAST we received
the “European Quality Award” in 2008
which opens up opportunities for new
cooperation.”
Ing. Pavel Veselý
Production Director, DSB EURO s.r.o.
27/12/2021
Success stories
The C.A.F.E module for metal simulation foresees the germination and therefore the growth of the grains and, allows to obtain a high sensitivity of the prediction of grain defects in solidification. Article in French
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27/12/2021
Success stories
THE CHALLENGE
Metalcast is casting increasingly complex parts in alloys that are difficult to cast. Yet Metalcast's customers expect them to continually meet their strict quality specifications and at the same time maintain or reduce product development time and expenses.
THE BENEFITS
. Multiple design iterations via simulation to reach an optimal design thereby reducing shop floor trials;
. Reduction in product development times;
. Rejections reduced from 25% to 3% on a valve body casting part.
27/12/2021
Success stories
Thanks to the development of dedicated techniques over the last two decades, investment casting modeling with ESI’s software has become reliable and efficient to optimize safety components such as turbine blades for jet engines. The solution includes dedicated superalloy material databases and ceramics characterization allowing very accurate predictions.
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27/12/2021
Success stories
Reduce part development lead-times by a better knowledge of process and an early confi rmation of metallurgical capabilities is one of the main topics for investment casting technology.
Numerical simulation is one of the major tools which can be used to face this goal. This e-tip illustrates a simulation methodology usable to optimize a casting design in an efficient and rapid way.
27/12/2021
Success stories
“Scientific methods can always save us time and cost. ProCAST is just that tool helping foundry men find the right solutions.
For investment casting process, ProCAST can generate different layers of shells and with wrapping outside. This helps predict the temperature field more precisely.”
Nannan Song,
Senior Researcher
Advanced Foundry and Rapid Prototyping Technologies, Inegi
