What Is Casting Simulation Software?
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| What Is Metal Casting Simulation Software |
This software also helps in designing mould cavities, multiple cores, padding, chills, exothermal material and gating systems (riser, runner, sprue, gate and pouring basin).
The software helps foundry engineers with the selection of material for the core, mould, tooling, padding, inserts, chills and ingots.
This software is utilized in the proper selection of the location of the mould core, inserts, risers, mould cavity inlet, exothermic materials and chills.
This results in simulating casting and the casting process eliminating defects, increasing yield and reducing the rejection of defective casting after production saving cost, material, resources, energy, time, money, labour, and investments ensuring proper delivery of accurate final casting to the customer.
The casting simulation software increases the confidence of the manufacturers, suppliers, product design engineers and production engineers in the casting process.
Softwares used for analysing, studying and simulation engineering metal casting components for simulation are NovaCast, Flow-3D, ProCast, MagmaSoft, AnyCastSoftware and TherCast By Transvalor Americas.
Types And Classification of Metal Casting Simulation Software Based On Casting Processes
- Sand Casting Simulation Software
- Die-casting Simulation Software
- Investment Casting Simulation Software
- Continuous Casting Simulation Software
- Centrifugal Casting Simulation Software
- Spin Casting Simulation Software
- Tilt Pour Casting Simulation Software
- Gravity Die Casting Simulation Software
- Metal Mould Casting Simulation Software
- Ingot Casting Simulation Software
- Lost Wax Casting Simulation Software
- Lost Form Sand Casting Process Simulation Software
Why Is Casting Simulation Software Used?
Casting simulation software is used in the manufacturing industry for the following reasons:
- Reduce the casting defects such as hotspots, cracks, shrinkage, porosity and warpages.
- Improve the casting yield during the casting process.
- Increases the profitability of the industry by reducing the rejection of the casting components and reducing the scrap rate.
- Produce accuracy of the complex shape castings.
- Challenge the engineers to design thin wall casting.
- Improve surface finish and texture of the final casting.
- Reduce the gap between the design and manufacturing departments.
- Improve the lead time of the production process.
- Increase the mechanical strength and properties of the casting.
- Reduce the overall downtime and monitoring of the casting process.
- Reduce the maintenance and breakdown time during the casting process.
- Design an efficient gating system that includes gating elements such as a gate, riser, pouring basin, sprue and mould cavity.
- Study the behaviour of the molten metal at the gating elements, during the pouring operation and solidification process in all phase transformations.
- Proper selection of casting material (mould, core, chills, padding, exothermic and ingots)
- Analysis of appropriate temperature for pre-heating of mould, solidification temperature and cooling.
- Proper selection of martial for mould, padding, pattern, chill and core.
- Improve the process of manufacturing castings with a clear goal mindset, simplify the design process and get an efficient result.
- This software helps in manufacturing planning, production planning, better designs, reduced lead time, increased production rate, reduced rework, reduced manufacturing errors and bringing manufacturing sustainability to the foundry.
Casting Simulation Software Application
What components, parts and products are designed, analysed and simulated using metal simulation software?
- Design of engine block and engine components such as piston, fuel injection system, cylinder, piston ring, crankshaft and crank.
- Machine bed and tables of lathe machine, milling machine, slotting machine, grinding machine and drilling machine.
- Design of complex components such as turbine, blades and impellers.
- Analysis of parts of motors, stators, alternators, generators, flywheels, governors and actuators.
- Parts of pumps and compressors such as blades, pistons, piston rings and cylinders.
- Gears are designed for spur gears, rack and pinion, worm gears and bevel gears.
- Parts of aircraft engines, car engines, rocket engines and machine engines.
- Gearbox, lever, clutch plate, brake, wheels, drums and disk.
- Design of shafts, crankpin, crankshaft, bearing, cam and followers, hinges, latches, knobs, pulleys, clamps, brackets, couplings and keys.
- Joins such as welding joints, rivets, nuts, bushes, inserts, screws and bolts.
- Casing design of motor, engine, gearbox, instrumental cluster and instrumental panel.
- Personel jewellery and ornaments such as earnings, rings, neckless, taira and bracelets.
- Design of figures, idols, bowls, car models and toys.
- Design and analysis of structural parts, beams and frames such as I-section, C-section, L-section and T-section billets and blooms.