product news/產品新聞 Custom Castings Uses Simulation to Eliminate Defects in Aluminum Part When Custom Castings, Winnipeg, Canada, tackled a
large 73-kg semi-permanent tilt pour job, it began pushing its equipment to the edge of its capabilities. Te metalcaster, a nonferrous metalcasting facility making aluminum and zinc alloy castings via the gravity permanent mold, semi- permanent mold and tilt pour processes, acquired the order for the 73-kg casting because a vendor producing it in grav- ity sand delivered castings that were cracking in service (Fig. 1). Custom Castings had been using Magmasoft by Magma Foundry Solutions, Schaumburg, Ill., for about a year to improve its casting quality and reduce sampling times. 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 simu-
lation during tooling development to evaluate the customer’s current casting design. By providing simulation results, it justified casting design changes that improved the castability of the part while maintaining its functionality in service. Te 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 a rigging system and process parameters that ensured unacceptable defects were not pres- ent in the casting. Having developed a robust gating and risering system
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 did not coincide with the simulations. Custom Castings in- volved Magma engineers to assist in resolving the issue. Te engineers first thought the large voids were due to
shrinkage porosity. Te simulation results were again reviewed and evaluated to check for errors that may have caused the discrepancy in results. Variations of material temperature, cycle times and mold temperatures were run to see if they would result in the observed defects. Trough all the varia- tions of parameters, the casting remained nearly defect-free
Custom Castings通过模拟减少铝合金铸件的缺陷 位于加拿大温尼伯格的Custom Castings有色金属 铸造公司通过研究铝合金和锌合金的重力金属型铸造、 半金属型铸造和相应浇注工艺，解决了73千克 的半金 属型铸造铸件的浇注问题，并开始进一步提升其铸造能 力。我们获得了这个的订单是因为之前采用砂型铸造的 铸件在使用过程中出现了裂纹（图1）。Custom Cast- ings公司为了提升铸件的质量并降低研发周期，采用由 Magma铸造公司提供的Magmasoft软件进行了为期一 年的模拟。结果显示对于金属型铸造来说，采用模拟可 以生产出更高质量的铸件。 Custom Castings也通过铸件模拟来评估客户的模 型设计。通过模拟结果，可以对模型设计进行相应的修 改，在保证铸件功能性的前提下，提高铸件的充型能 力。Custom Castings公司可以及时提供符合质量要求 的订单，这样新型铸件的生产就变得易如反掌了。在设 计更改被批准后，工程师就可以设计相应的系统和工艺 参数，以保证铸件的缺陷都在预测之中。 设计调整好合适的浇注系统和相应参数后，为了验 证模拟结果的准确性，Custom Castings公司会预先 浇注一批试件。但是第一批试件存在体积较大的空洞， 生产和模拟结果并不匹配。Custom Castings公司请 Magma方面的工程师来协助解决问题。 工程师们起先认为空洞是由于缩孔产生的，并对可 能产生模拟与生产差异的结果进行了审查和评估。通过 修改浇注温度，生产周期和模具温度，看是否可能模拟 出实际生产中的缺陷。但无论如何调整参数，模拟结果
Fig. 1. Parts originally produced via gravity sand casting were experiencing failure defects in service.
图1.经过重力砂型铸造 的铸件在使用过程中出 现裂纹
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FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION Fall 2011
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