CASTING INNOVATIONS
EGR Valve Redesign Relies on Simulation After winning business from
a competitor, Epcor (Cincinnati) needed to produce complex exhaust gas recirculation (EGR) valves for an automotive parts manufacturer. Most modern engines use this emissions reduction technique to meet auto- motive emission standards, and the valves must be manufactured to high standards. Te challenge for Epcor was to produce these parts quickly and without flaw. Te standard approach for
metalcasting is for patternmak- ers to design molds based on their own experience. Tis method is less than optimal for various reasons, the number one reason being that the initial design is rarely viable. In the case of the EGR valve, Epcor knew it could not meet the customer’s ag- gressive delivery requirements using the traditional approach. Terefore, after evaluating different casting simulation tools, Epcor turned to
Fig.1: An initial QuikCAST simulation shows shrinkage porosity present in the casting.
ESI QuikCAST. In addition to it being an affordable solution, Ep- cor liked the fact that QuikCAST linked them to ESI’s more
comprehensive casting simulation program, ESI ProCAST. To begin, Paul Kiefer, Senior Design Engineer for Hitech Shapes
Epcor needed to produce complex exhaust gas recirculation valves for an automotive parts manufacturer, and the challenge for Epcor was to produce these parts quickly and without flaw.
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