. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Casting innOVatiOns
Custom Castings Uses Simulation to Eliminate Defects in Aluminum Part
permanent mold and tilt pour processes, tackled a large 160-lb. semi-permanent tilt pour job, it began pushing their equipment to the edge of its capabilities. The metalcaster acquired the order for the 160-lb. casting because a vendor producing it in gravity sand delivered castings that were cracking in service (Fig. 1). Custom Castings had been using Magmasoft by Magma Foundry Solutions, Schaumburg, Ill., for about one year to improve its casting quality and re- duce sampling times, and using the software, it was able to show it could provide the casting with better mechanical properties through the permanent mold process. Custom Castings continued to use casting process simulation during tooling development to evaluate the customer’s current casting design. By providing simula- tion results, it justified casting design changes that im- proved the castability of the part while maintaining its functionality in service. The new casting was easier to produce, which allowed Custom Castings to provide the order on time and to the specified quality level. After the design changes were approved, the metalcaster began developing an appropriate rigging system and process parameters that ensured unacceptable defects were not present in the casting. Having developed a robust gating and risering system
W
hen Custom Castings, Winnipeg, Canada, a nonferrous metalcast- ing facility making aluminum and zinc alloy castings via the gravity permanent mold, semi-
Fig. 1. Parts originally produced via gravity sand casting were experiencing failure defects in service.
along with all the necessary process parameters, Custom Castings verified the simulation work by running a batch of samples. But it hit a glitch upon running the first batch. Large porous voids were present in the casting, which
Fig. 2. First casting samples at Custom Castings exhibited porosity, which did not correlate with initial process simulation results.
Fig. 3. In order for a core to emit a gas, uncured binder in the mold must reach high tempera- tures. Shown are simulations for core tempera- ture of the part at the start of filling (left) and at the end of filling (right).
48 Metal Casting Design & PurChasing MarCh/aPril 2010
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