Fig. 1. Shown are the results of yield strength simulation predictions and actual measurements for B206-T4 aluminum.
each serial numbered section, picking from the range of wall sections avail- able. Te aim was to include bars from both chilled and non-chilled areas of the casting. Personnel turned 0.25-in. diameter bars from the thinner walls and 0.5-in. diameter bars from the larger sections. In the course of about two months all the bars were cut and pulled, with data compiled. Eck then worked with its simulation software provider to make the adjustments.
Data Crunching Eck had already made arrange-
ments for further software training with its simulation software sup- plier, and creating the new datasets for A206 and B206 (both in T4 & T7 conditions) was an added agenda item. After a few days of data crunch- ing and comparisons between actual results and simulation results, Eck and its software provider completed its calculations. Te general data-spread was accurate within about 10% to the actual test bar results. Now, Eck can toggle through
simulation results that map predicted tensile, yield and elongation of A206 and B206 in either the T4 or T7 con- ditions (Fig. 1). Images can be shared with customers, and the data is based on the metalcasting facility’s actual
process, not another plant’s. Te idea of using simulation to design a gating system to reduce turbulence and porosity is helpful, but Eck discovered and developed tools to design a gating system that can be driven more by customer property requirements. Tis analysis can be replicated in other metalcast- ing facilities using their own software system—with good communication from their provider—to customize
solidification modeling to take into account melting practice, heat treat- ment and other processing parameters to be more accurate and predictive of actual mechanical properties. Eck Industries has found this tool
to be particularly handy in helping its customers understand how mechanical properties will vary in actual castings and designing property-driven gating, risering and chilling schemes based on customer needs.
Eck Industries is using the analysis of its new software tool as part of development for the CHAMPS A206 program. Here, elongation properties are predicted.
June 2013 MODERN CASTING | 31
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