process design process modeling process simulation...
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Casting Design Research
Process designProcess modelingProcess simulationOpportunities
Design for Manufacturing 2
Casting System Components
Design for Manufacturing 3
Casting System Components
Design for Manufacturing 4
Metalcasting Lead Time & Cost Reduction Project
Objectives:Define an integrated casting design environmentDetermine the capabilities of existing softwareConsider both expendable mold & permanent mold processes
Tasks:Complete surveys of software suppliers & usersDetermine current industrial practice with casting softwareEvaluate costs & benefits of casting design softwareDefine scenarios for foundry use of softwareDevelop functional design of an integrated casting design environment
Design for Manufacturing 5
Casting Process Design
Part orientationParting line locationGate(s) and riser(s) designPattern/mold designProcess simulation
Design for Manufacturing 6
Casting Design Environment
Shared Database • Part & mold geometry • Casting material properties • Mold material properties • Process types & characteristics
CAD System
Laser Scanning
CAE Applications
• Dynamics • Heat transfer • FEM • Design optimization
Performance Capability • Resource availability • Time estimation • Cost estimation
Activity Manager
CAM Applications
• CNC machining • Rapid prototyping
Process Simulation
• Fluid flow • Heat transfer • Solidification • Stress growth • Defects/Quality Criteria Functions
Pattern/mold Design • Parting line location • Allowances & draft • Rigging system • Tolerance specification • Shape constraints
Design for Manufacturing 7
Integrated Casting Design Software Environment
Design for Manufacturing 8
Casting Design Software Functions
Design for Manufacturing 9
Casting Model
Input Parameters• Part Geometry• Part Material• Tolerance & Finish• Production Requirements
Process Design• Casting Process• Parting Line Location• Gating & Risering
Model Output• Casting Geometry• Production Cost• Solidification Time• Stresses & Defects
Design for Manufacturing 10
Casting Process Simulation
Casting Simulation Using MAGMAsoft– XM35 Rotor•Part design•Simulation model•Simulation results•Redesign iterations
Design for Manufacturing 11
Continuous Casting Research
Continuous casting processWorkflow – production planningIPSCO Caster model – process planning
Design for Manufacturing 12
Continuous Casting Process
Design for Manufacturing 13
Continuous Casting Model
NeuralNetwork
ThicknessWidthCarbon%SuperheatCasting SpeedCooling Rate
Mean
StandardDeviation
Design for Manufacturing 14
Optimization Scheme
Design for Manufacturing 15
Questions & Answers