innovations CASTING
Institute Offers Cloud-Based Simulation Lab
C
onsidering the growth of automation, CAD and simulation technologies, the metalcasting industry faces an opportunity to
coordinate and cooperate like never before. One professor at Mumbai’s Indian Institute of Technology (IIT) Bombay is hoping to use develop- ing technology to educate, train and provide experience for metalcasting students, experts, and design and pur- chasing professionals. Dr. B. Ravi, mechanical engineer-
ing professor at IIT, has launched the E-Foundry Network, a free online resource focused on casting design and simulation. T e heart of the E- Foundry is a cloud-based simulation lab powered by a quick simulation algorithm that allows users to upload a 3-D CAD fi le and view solidifi cation temperatures in minutes. T e casting model is uploaded to
the E-Foundry server, which checks the fi le, generates a 3-D view and sends the image to the user’s device for visual verifi cation. After user confi rmation, the simulation program on the server sub- divides the casting model into a fi ne or coarse mesh, computes the solidifi cation temperatures, and post-processes the results to generate color-coded images.
The simulation lab allows users to upload CAD models and view solidifi cation simulation results within minutes.
T e user can save the images for future reference, all in less than 10 minutes. T e color-coded results show the relative temperatures in diff erent regions of the casting at the instant of solidifi cation of the hottest region, allowing users to identify hot spots, cold spots and high gradient regions. Based on these results, engineers can model the feeders, verify their design (location, shape, and size) and upload the model to the Sim Lab. Product engi- neers can check and modify part design (wall thickness, tapers, ribs, fi llets, etc.) to ensure directional solidifi cation and
ease of feeding. Tooling engineers also can determine the most appropriate orientation of the casting in the mold to ensure it can be fed and fettled. “T e initial response has certainly been encouraging,” Ravi said. “Going forward, the E-Foundry team would like to involve other experienced teachers, consultants and industry experts, and develop a larger global platform for the exchange of knowl- edge and best practices.” Supported by the Indian govern-
ment’s National Knowledge Network, the project is handled by IIT Bombay, which supplies content and updates the website. Since its launch at the start of 2013, the website has attracted more than 53,000 visitors and 3,200 members. T ose members have simulated more than 6,500 castings on the cloud. While a majority of visitors are from India, the site is gaining views from the U.S., Ger- many, China and other countries with developed metalcasting industries. Other facilities include an on-
The E-Foundry includes a variety of educational tools that are free to all visitors.
line classroom, library and tutorials. Additionally, the projects page and discussion hub are resources that al- low E-Foundry members to interact. T e Hub contains discussion threads focused on technical questions, and the Projects page includes updates to ongo- ing research and profi les those involved with the projects.
Nov/Dec 2014 | METAL CASTING DESIGN & PURCHASING | 45
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