Process design Process modeling Process simulation ...user.engineering.uiowa.edu/...Casting_Design_full.pdf · Design for Manufacturing 5 Casting Process Design Part orientation Parting

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