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Casting-compatible designs
We develop casting-compatible designs for aluminium and iron castings.
Long years of experience in our production areas for model and tool making, casting and machining are the basis for the design and calculation of components that are functional and ready for production. In addition to our experience and technological/scientific expertise, we are targetedly using simulation for the evaluation and development of castings. Structural-mechanical and thermal requirements as well as the manufacturing possibilities and the limits are taken into consideration.
The goal is to produce components and tools for our customers that are technologically and economically optimised.
Castability of a cast metal design part
At the very beginning of a design ready to be cast, the castability of a cast metal design part, together with the mechanical characteristics are analysed by means of 3D simulation and also developed further in the simulation model. The geometry, the casting system and the process development are the focal point of the examination, with the goal to be able to produce defect-free, light and almost warp-free castings
The relevant product geometry and the product specifications mentioned do refer here to the subsequent mass production. In order to implement the thermal and mechanical characteristics of the series product for the prototype and preproduction parts, the casting process for series parts and the process for prototype casting is being compared.
Numerical casting process simulation
Using numerical casting process simulation, it is thus possible to analyse thermal and mechanical profiles and to design the casting system for prototypes such that, in terms of quality, the casting process and the solidification process take place in a similar manner to that of the samples cast for mass production.
The casting-compatible designs and the process control are developed in simulating various variations and then implemented directly in practice. In the end there is an optimised cast product that we produce with the manufacturing process that makes sense for the respective product. Here, we have available to us both prototype and series processes.