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CASTING INNOVATIONS


metal pushing into the area of the erosion (Fig. 2) with a velocity that was quite turbulent, which indicated the same problem seen on the production fl oor. T e engineering team increased the center shaft diameter


and radius to slow the velocity around the problem area. T e simulation showed considerable decrease in fl uid velocity going up the shaft compared to the baseline model. T is led to less turbulence, and as a result, less fl uid pressure around the concerned region. T is lowered the chance of fl ash in the problem region, which reduced potential die erosion. Further iterations were run to fi ne-tune the fl ow balance, which could further reduce die erosion. Once these design changes were applied in production


trials, the sample runs showed promising signs of improve- ment. T e die erosion was signifi cantly less and the down- time to repair the die was reduced by 81.2%. “T e traditional approach of relying on experienced designers to defi ne the die based on what worked on similar projects in the past rarely produced a design that met our requirements,” Kreitzer said. “So we had to run tests on the machine to work out the problems. Now, computer simula- tion makes it possible to evaluate the performance of the die prior to building hardware. We have found ProCAST pre- dictions to be very accurate, and simulation provides more information than what is obtained during testing.” T e resulting visualization of the casting process helps engi- neers understand the causes of defects and evaluate the perfor- mance of modifi ed tooling designs without having to actually produce tooling. “As a result, we have been able to substantially reduce the number of die tries and compress the entire product development process by several months,” Kreizer said.


CASTING INNOVATIONS


Bring in Leads. Sell More Castings.


• Promote your capabilities in detail to a targeted audience of extremely interested contacts


• Establish your company as a trusted source for reliable information on a specifi c topic


• Develop a sales tool with long-term benefi ts


• Earn valuable highly qualifi ed short-term leads for your sales team!


Advertise. Jim Beckwith,


jbeckwith@afsinc.org 800/537-4237


Webinars With


To view the Eck Industries webinar, visit www.metalcastingdesign.com/eckwebinar.


Fig. 2. The simulation showed metal pushing to the area where the die erosion was discovered.


METALCASTINGDESIGN.COM January 2015 MODERN CASTING | 49


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