The main goal was to optimize the process conditions of the existing mold layout. This core, called the Shinwest Core, poses the greatest challenge to the production of Usiminas scores. Its length (920 mm), significant changes in the direction of sand flow during injection, the need to backfill certain parts of the core due to backflow, and cross-sections within the core.
Metal casting software is one of the best casting process simulation programs which offers a number of benefits to the casting industry.
First trials showed problems with the process, which led to a complete collapse of the lower part of the core. The core blowing and curing steps for the PU coldbox process were analyzed, making it possible to draw preliminary conclusions regarding the existing defects.
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Casting process simulation software considers the complete casting process including mold filling, solidification, and cooling, and also provides the quantitative prediction of mechanical properties, thermally induced casting stresses, and the distortion of cast components.
Simulation accurately describes a cast component’s quality upfront before production starts, thus the casting layout can be designed with respect to the required component properties.
This results in a reduction in pre-production sampling, but also the precise layout of the complete casting system leads to energy, material, and tooling savings for the foundry.
The software supports the user in component design, the determination of melting practice, and casting methodology through to mold making, heat treatment, and finishing. This saves costs consequently along the entire casting manufacturing line.