Metalcasting Industry Roadmap
b. Educational Tools / Knowledge Transfer ± This relates to information on common manufacturing processes and access to casting expertise. Educational tools for common manufacturing processes should use iconic products to illustrate the processes. A simple way to promote understanding of the capabilities of major casting manufacturing methods is to tag them to commonly made products. This will show neophytes where these processes have historically worked best. With the support of industry and academia, examples of optimal casting processes should be provided along with the rationale to explain the unique capabilities of the different casting methods. This can be set up in an open-source format such as a wiki where the community can be involved and add to the details; thus, constantly evolving the knowledge base.
Key Tasks
x Develop a web-based tool x Illustrate common processes x Give examples of ideal processes
Target Outcomes
x Easily accessible resources for self-guided and directed casting education x An enabled next generation of designers and manufacturers for cast parts
c. Metalcasting-Specific CAD Modules ± These are tools to increase the manufacturability of cast designs. For example, a simple thin wall and thick sections analysis tool to look at transitions would provide important information to a foundry for feeding a casting as it solidifies. Simple design tweaks based upon section size analysis could increase the manufacturability of cast designs. Lightweighting technology is inherent in cast geometry as metal can be placed only where it is needed, which is a specific advantage of cast parts. Further enhancing this through high performance alloys and designing for weight reduction can increase lightweighting opportunities, which are critical in many industries. Modeling technology that can convert an optimized FEA into cast geometry would enhance this opportunity. A tool that makes design tradeoffs within a casting such as knowing how design decisions impact the manufacturability of a casting will facilitate the design of complex parts, and assist foundries in working with new designers who are inexperienced. Non-centric manufacturing design tools allowing a part to meet the performance requirements of a system versus being artifacts of CAD systems are important to ensure the optimization of the manufacturing process. Incorporating thermophysical properties of alloys, molds, and cores, as well as heat transfer coefficients will improve the modeling capability of existing software. Room temperature properties are commonly known for most materials; however, castings are made above the liquidus point of metals. Thus, knowing properties at temperatures for the metal and mold during the manufacturing process are needed to develop accurate simulation software.
Key Tasks x Implement solidification modification (thin wall / thick wall section analysis)
44 Design
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