ing various methods, including stereo- lithography. Our most used references are the ASM Metals Handbooks. The one thing that the design com-
munity is in need of is competent design engineers. It seems that cast- ing materials and manufacturing pro- cesses are not taught very well or are forgotten by the engineers entering the fi eld. I fi nd it frustrating that en- gineers select materials without even looking up the textbook values for needed properties, such as strength or impact resistance. In addition, competent engineers with experience are expensive.
Designer: Jiten Shah
COMPANY: Product Development & Analysis (PDA) LLC, Naperville, Ill. POSITION: President We use computer aided engineer-
For one designer, the most used tool was ASM Metals Handbooks.
ing tools, such as SolidWorks, fi nite element analysis (FEA), computational fl uid dynamics and casting process simulation for mold fi lling, solidifi ca- tion and microstructure. We run these tools on state-of-the-art, powerful PC workstations running Windows. The CAD tools we use translate well
to casting design with their capabilities for drafting, parting-plane develop- ment, and mold design, including core extraction, fi llet, etc. In addition, we use our own li-
brary of casting process capabilities for various alloys and processes, value engineering tools, design failure model effects analysis and process failure model effects analysis tools, some of which we have embedded into proprietary, web-based tools developed by PDA working with metalcasting industry trade groups. For background information and ad- ditional resources, we typically tap into industry trade group websites, includ- ing the American Foundry Society’s Virtual Library, and the Metal Casting Design & Purchasing website and on- line metalcaster directory. There is a need for a selection
tool for rapid prototyping processes for a new casting development pro- gram. The tool should take into ac- count the quantity, overall part size and complexity, surface fi nish and dimensional tolerances required, as well as the mechanical properties for functional testing and valida- tion. Also, there is a strong need for a thermo-physical properties data-
46 METAL CASTING DESIGN AND PURCHASING SEPTEMBER/OCTOBER 2010
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