ProCAST General Presentation 5

THE

VIRTUAL

TRY-0UT

SPACE”

COMPANY

Case Study 4
steel Investment Casting

_CRKEATE


=EST GROUP,

Case Study - Steel Locking
Jaws

@ Gas and shrinkage porosity were observed in
the initial design of the cast freight trailer
component.

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THE

ESI GROUP

VIRTUAL

T#Y-OUT

S%PACEF* COMPANY

Case Study - Steel Locking
ϬvAzr=¬

Mesh
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Case Study - Steel Locking
Jaws

ESI GROUP

“ee

-`
`

Ot

Beg,

*—————-

.....

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The air cannot escape

» \

X _

Vy

'Eltlucnarune

STEP NUMBER = 132

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Animated image

from the lower castings,

because the upper ones

are filling too early.


'~EST GR0UP

Case Study - Steel

Locking
Jaws

This filling problem due to an ineffic

tree design leads to entrapped air
in the casting.

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_'
Case Study - Steel Locking
Jaws

Solidification
contour plot.

VIE

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PRACTION SOLID

STEP NUMBER = 279

Animated image

Case Study - Steel Locking
Jaws

_=ESI GROUP

Macroporosity
(shrinkage porosity)

ACRO POROSITY
SIEP NUMBER = 849

=

=
m

contour plot.

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Case Study - Steel Locking
Jaws
Macroporosity predicted by simulation, and by X-Ray analysis

IACRO POROSITY

Copyright ©

ESI Group.

2007. All rights reserved.


ake Nou:

Case Study - Steel Locking

Jaws

Change in process
design, in order to
avoid entrapped air
and reduce shrinkage
porosity.

At EMPERATURE

STEP NUMBER = 140

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|

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THE

VIRTUAL

TRY-OUT

SPACE”

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COMPANY

Case Study - Steel Locking
Jaws


THE

ESI GROUP

VIRTUAL

TRY-OUT

SPACE”

Conclusion

COMPANY

@® Selected customers in investment casting, mainly in the aerospace
industry: A/stom, PCC Airfoils, PCC Structural, Howmet, Snecma,

FHolls Royce, EMA, Doncasters, Microfusione Stellite, Centro Sviluppo
Material, Microcast, Microsteel, Precicast, AIDC, Bet Semesh,
Stryker Howmedica, MFL, GE, Pratt-Wittney, Mitsubishi,
[shikawajima Precision Casting, Starmet, Cercast, SALUT, Harbin
Donkan Engine, Shenyang Liming Aero-Engine Group, Xi'an Aero
Engine company...

"For several years, ProCAST has been used at Howmet for customer concurrent engineering,
development of new components and optimization of our investment casting processes. ProCAST
allows us to quickly optimize our gating systems in terms of filling and solidification. Simulation
results are then stored in a technical database used by our product and process development
department."
Loic CALBA, CAD & Process Modelling Manager, Howmet S.A.S., France

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THE

VIRTUAL

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COMPANY

Case Study 5
steel Sand Casting

_CRKEATE


_=ESI GROUP

Case Study - Steel Sand

@® Production problem solved with casting simulation
@®

Primary & secondary shrink porosity in critical areas

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Casting


|Ses

GROUP

Case Study - Steel Sand
Casting
First iteration:

Initial design modification
of back shroud section.
(top view).
This concession allowed
elimination

of five top risers (bottom
view).

Copyright ©

ESI Group.

2007. All rights reserved.


WPEio.,

Case Study - Steel Sand
Casting

Exploded view of mould
assembly.

Copyright ©

ESI Group.

2007. All rights reserved.


.`>EST GR0UP

Case Study - Steel Sand
Casting

Ns

ae

Arrow shows

shrinkage

location

on front shroud.

CE tN

Noo

Suy
x

7
VÀeke ee CÀ
ma

San
tái

và”
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bÓ

ASe

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Đà
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EH
PK)

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Dos

a eae. \ ĐẠI

vi

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al

ee:aot ly,

2, et

ee

hài 4‹l SàvệAt

Copyright ©

ESI Group.

2007. All rights reserved.


By

sacs

vase Study - steelCasSan
d
ting
v.

`

ch
t3
Hy
sea

Then solidification
progressing from
casting to risers.

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te ie

a

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vi

+ hà

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xế

a

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tie
Tey

a) Pera La

A KẾ Be)

rr

ư

ener

gr
Re
Re
KS

ve

aa

5 eI
ro 0617270,
v4

Copyright ©

ESI Group.

2007. All rights reserved.


Case Study - Steel Sand

_=ESI GROUP

Casting

TLL

Ji

A

The macroporosity plot
shows shrinkage defects
at each shroud-vane
junctions.

805E+03 $,
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S00000E+01 s


"=1 €,00)0),

Case Study - Steel Sand

Casting

Secondary shrinkage at
riser-hub connection.

Not a major concern as
defect would be visible
after removal of riser, and

repaired.

RO PO
STEP NUMBE
TIME = 2

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Second iteration:
1. Chill size was

increased.

2. Riser diameter was

increased.
Copyright ©

ESI Group.

2007. All rights reserved.