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Construction of the casting

First, we check the castings based on the available CAD drawings on a production -proven design. Only when the component is suitable for the production of a permanent mold , we start with the construction of the casting tool .
 
 
 

Optimization of the casting

 
 

FEM calculation

With a FEM calculation can determine various parameters in the casting . It is mainly used in order to optimize the properties of the casting.
 
In the FEM analysis (FEA = finite element method) are calculated with the help of special applications parameters in a cast part .
 
These include, for example :
 
• Strength
• Voltage
• Strain
• Heat
• Pressure
 
 
Procedure
In a FEM calculation is going on in most cases after the IPO principle . That is, a component is firstly created in a CAD program. Through an interface or an interchange format ( STEP , IGS) , the data are loaded into a preprocessor. A preprocessor is also a software. In the preprocessor , the component is provided with conditions and prepared for the FEM calculation . In the next step, the file is loaded into a post-processor . In this software , the actual result is determined .
 

Topology Optimization

The topology analysis shows large savings especially in castings . But it has two positive effects. Firstly, the topology study shows possibilities for saving component weight . But especially during prototyping is reduced , this also tremendously the required amount of raw material. This has a positive effect from the cost of production and therefore the component costs . This means that not only weight , but also much cost can be saved through the topology analysis.
 
DICASOL accompanies its customers from the development to the production stage . The topology of this analysis comes at a very early stage of the game. Because it is largely responsible for molding of components. The examination of castings by a topology analysis can be straight with builders of considerable advantage and has enormous potential for savings . In shaping parts , however, the topology study is not appropriate . Because the topology analysis takes no account of design and style. It is only used to realize the forces to be transmitted through a minimum of material .
 
Procedure
For a topology investigation , the casting must first be prepared in a CAD program. That is, it must necessarily required design features are incorporated . Examples include holes and grooves. Then all the forces that occur later on the component applied . Thus , the casting for a topology study is prepared. The software then calculates the locations at which material can be saved.
 

Production-oriented design

 

Demoldability

The satisfactory releasability of a cast part , which is produced with a continuous form , is essential. Only if the component can be removed from the mold , can be used more economically permanent mold . For non demoldable components so-called lost forms must be used. The manufacturing process of lost molds is time-consuming and therefore costly . Using special software , we examine the construction of the casting primarily on draft angles and undercuts as well as provide in this way ensure the smooth mold removal .
 

Flow section

The flow cross-section in a cast part is a crucial parameter for the degree of filling and the filling speed . Thus, the flow cross-section is also an extremely important factor for short production times and a low rejection rate . Based on our experience and with the help of CAD software, we identify vulnerabilities in relation to the flow cross section of the casting. We prepare the ground for a perfect filling of the casting tool , and therefore an efficient production and lower component costs .