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Molding Process. Heat Treatment. A bar chart quickly displayed both defined objectives for each considered design. In doing so, opposing trends regarding porosity and hot tearing became obvious. The strongest tendency for hot tearing was revealed for an optimum feeding with minimum porosity. This is due to longer solidification times and increased temperature differences between the casting and the feeders, which promotes feeding, but also results in high strain rates and an increased tendency for hot tearing.
The bar chart also allowed the engineers to quickly identify a design that provided the best compromise between the two competing objectives. A comparison of the results between the original situation and the best design considered in the optimization showed that geometric changes in both the casting and in the feeding system were necessary to significantly reduce the stress and porosity defects at the same time.
Indications of hot tears in the original left and in the new design right. Thanks to the positive results, it was possible to reduce both the amount of magnetic particle inspections required as well as the amount of re-work time. The calculation of these 12 versions was done on an 8-core workstation and took To run samples in production to test all 12 versions would have taken weeks, with material and labor costs that could not have been justified.
Without optimization to quickly consider all 12 designs, the changes made to the tooling would not have been possible in this case. The systematic use of autonomous optimization at Eagle Alloy has contributed substantially to enabling the cost-effective production of quality castings for this case study.
Eagle Alloy , located in Muskegon, Michigan, USA, was founded in to meet the needs of customers looking for a short-run steel and stainless steel foundry. Today, Eagle Alloy is a medium to high production steel foundry that competes globally and is considered to be one of the finest overall steel foundries in the USA. EN KO. Toggle navigation. MAGMAsteel 5.
Mold filling of a turbine housing. Filling and cooling of the melt during casting. Distribution of reoxidation inclusions on the casting surface. Porosity indications. Autonomous Optimization for determining the required number of feeders. Manganese concentration profile after solidification. Sand burn-on and penetration tendencies.
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