Die casting - Engineering Analysis
- 1. DIE CASTING – ENGINEERING ANALYSIS Dr. N.Ravichandran ValueSource Engineering Services www.valuesource.tech
- 2. This is the second Webinar being delivered to attain “Excellence in Industrial Manufacturing Processes”. We share knowledge and experience to nurture manufacturing talents, by disseminating information on recent Technological Trends along with needed “Best Industrial Implementation practices”. OBJECTIVE
- 3. Die Casting Technologies have significantly improved Productivity in foundries, albeit high initial investments. Systematic sequencing and optimizing of “cycle times” of die casting production process steps is essential for realizing the productivity advantages. The optimum “cooling schedule” offering casting integrity and microstructure is best evaluated using simulation techniques. The conflicting requirements of good feeding at faster cooling rates necessitates quantitative analysis. Simulation supported by visualization capabilities of complex parameters and statistical optimization procedures greatly facilitates such Engineering Analysis. Case studies on intelligent die designs exploiting concepts such as conformal cooling, distributed feeding centers, pressure assisted feeding will be presented in the webinar to demonstrate the importance of deploying productive tools for systematic ideation of “cycle time” gain in die casting processes.
- 4. Conformal Cooling IDEATION CONSTRAINT ENABLERS INNOVATIONS Feeder volume, geometry, location, insulation; Thermal inertia, Freq. and mag. of thermal load cycles on dies; Engineering Analysis and Simulation Distributed feeding Pressure assisted feeding;
- 5. 4 Box Problem Solving Framework User’s Specific Problem Generalized Problem Generalized Solutions User’s Specific Solution Abstract Generate Solution Concentrate (Or) Confine
- 6. Engineering Tools as Generic Problem Solvers User’s Specific Problem Generalized Simulation Problem Generalized Simulation Solutions User’s Specific Solution Abstract Simulated Solution Concentrate (Or) Confine
- 7. 4 Spheres of Engineering Activities in Manufacturing Process Design Tooling Design Micro- structure Product Design
- 8. Schematic - Progressive Trends in Die Casting CAPABILITY LPDCGravity Die Casting Sand Casting HPDC Minwallthickness Productivity FeedingEfficiency CastingYield SolidificationRates CastingReliability
- 9. PROCESS DESIGN Innovation Engineering Analysis as motivator Aiding Simulation Illustrative Pictures Suggestions
- 10. ACCELERATED GROWTH IN PRODUCTION CAPACITY New Technology or Equipment capable of making products at 50 – 100 time faster than the present speed, is introduced in production line, that demands a re-look at the process fundamentals Product Wr Universal Machine, Lot qty Special Machine, Lot Qty. 20 gm 21-500 g 501g – 1o Kg 10 t0 50 Kg 10,000 5,000 1,000 1,000 500,000 50,000 20,000 10,000. Design Process and Process Parameters to match the pace of mechanization
- 11. Directional Cooling
- 12. Directional Cooling an increase of cooling rate from 0.19 to 6.25 C/s decreased the SDAS from 68 to 20 lm
- 13. Directional Cooling
- 14. PROCESSING TEMPERATURES
- 15. TOOLING DESIGN
- 16. Cooling Channel Design Cycle time benchmarks Process Costs Enhanced cooling rates Intelligent heat extraction Reduced energy input
- 17. INSTRUMENTATION FOR THERMAL MANAGEMENT
- 18. DIE ELEMENTS
- 19. MICROSTRUCTURE
- 20. SAMPLE GEOMETRY TO PROPERTY
- 21. SAMPLE GEOMETRY TO PROPERTY
- 22. SAMPLE STANDARDS PREPARATION
- 23. SAMPLE STANDARDS PREPARATION
- 24. WEIBULL ANALYSIS OF TENSILE STRENGTH
- 25. PRODUCT DESIGN
- 26. ACCEPTANCE STANDRADS
- 27. PART DESIGN - FOUNDATIONS
- 28. RISK ASSESSMENT
- 29. RELIABILITY ANALYSIS Filed Performance Data Warranty Failure Data Release Approval Validation Data Release Validation Test Data In-Process inspection Data Stage – Inspection - Data Process Release Capability Data Process Validation Approval
- 31. Data Flow and Analysis Process Design Tooling Design Micro- structure Product Design
- 32. BUSINESS POTENTIAL LPDCGravity Die Casting Sand Casting HPDC WallThickness,CycleTime,SurfaceFinish
- 33. Engineering Analysis in Process Design Tooling Design Microstructure Product Design Is crucial in Manufacturing INFERENCE
- 34. Engineering Analysis is vital for converting “MANUFACTURING” challenges” to “OPPORTUNITIES” Die Casting Industries must build eco-system for “Engineering Analysis” and nurture culture of knowledge sharing. There is Rapid Advances in the area of digital tools for Engineering Analysis. Successful Adaption of such Analysis Tools have demonstrated.
Industrial forging processes
- 1. INDUSTRIAL FORGING PROCESSES – EMERGING TRENDS AND OPPORTUNITIES Dr. N.Ravichandran ValueSource Engineering Services www.valuesource.tech
- 2. INDUSTRY
- 3. GLOBAL BUSINESS SHARE
- 4. Forging is the most favored process step for manufacturing safety critical structural components. Being a capital intensive up-stream process, yet far away from the line-of-sight of customers’ value proposition, hence is at the receiving-end of dominantly buyers’ market. Incumbents must create value created by engineered continuous improvements to off-set the technology edge of new entrants. The webinar shall identify potential developments in forging process to synergize legacy with technology, for sustained economic growth. Forging Die Design Process Innovations Dynamic Materials Modeling Deformation Processing Maps Energy Saving Options Pacing Upgradation
- 5. Business Transformation from Traditional to Engineering Companies 1.Technology transfers 2. Technology Deployment • Engineering Analysis • Analysis Tools • Quality Data • Operation Data
- 6. Part Design Die Design Process Design Material Related Workability Opportunities
- 7. PART DESIGN
- 8. Additive Manufacturing - Opportunities - Topology Optimized for AM - Intermediate to AM is Forging Mobility Sector - Electric Vehicles - High Speed Trains - Aerospace sector
- 9. FE Analysis Topology Optimization Part Integration Light weighting Process Preference PART DESIGN
- 10. PART DESIGN Geometries at Intermediate stages are new opportunities for forging to compete
- 11. Die Design & Process Design
- 12. DESIGN OPTIMIZATION
- 13. DESIGN OPTIMIZATION (i) preform optimisation, (ii) relief hole and (ii) relief axis.
- 14. DEFORMATION STRAIN STRAIN RATE EFFECTIVE STRAIN von Mises Stress STATE-OF-STRESS WORKABILITY STATE - OF – STRESS RELATED WORKABILITY INTRINSIC WORKABILITY MATERIAL RELATED WORKABILITY ENGINEERING ANALYSIS UP-SETTING ROLLING EXTRUSION BLOCKING BLOW EDGING BLOCKING TRIMMING FE Analysis & Simulation
- 15. DESIGN OPTIMIZATION Consider shape and size of the initial billet and predict the forces needed as well as the defect occurrences. Extend hot forging die life by • minimizing the damage accumulation • developing optimal preform design. Consider Die-elasticity, secondary yielding, spring-back and temperature involved. Optimum Preform shape also should consider improved dimensional accuracy of the forged parts Die and Process Optimization for Improved Material Yield
- 16. Selection of appropriate Materials constitutive Equation in simulation
- 17. DESIGN OPTIMIZATION – Case Study
- 18. DESIGN OPTIMIZATION – Case Study
- 19. PROCESS OPTIMIZATION – Case Study
- 20. PROCESS OPTIMIZATION – Case Study
- 21. MATERIAL RELATED WORKABILITY (Huge Opportunity for Business Growth)
- 22. Constitutive Equation
- 23. Dynamic Material Modeling
- 24. Deformation Processing Maps
- 25. Deformation Processing Maps (Prasad Maps)
- 26. Duplex low-density Fe–Mn–Al–C steel
- 27. Engineering Analysis plays a vital role in converting challenges to opportunities. Identifying the right tools and nurturing strong engineering teams is key to success Process data and analysis can significantly improve business performance Adapting the emerging workability characterization techniques help in entering into strategic and advanced materials domain. CONCLUSIONS
- 28. THANK YOU