Would You Like To Get More Good Castings Shipped?

Would you like to get more
good castings shipped?

Christof Heisser
MAGMA Foundry Technologies, Inc.
Carlos Esparza
PurePower Technologies
AFS 75th Wisconsin Regional Conference

February 27- March 1,2013 - Milwaukee, WI USA
Ductile Iron HighSiMo Turbo

Housing Development using
Simulation
Carlos Esparza
PurePower Technologies

March 1st, 2013

Turbo Housing

Turbo Housing
Road to Find Perfect Castings
V01
V06
(Tooling
Construction)
V02
1st Sample
Some
Shrinkage as
Predicted
2nd Sample
Reduced
Shrinkage
Level
as Predicted
V14
V04
V13
PPAP Run
Shrinkage
Eliminated
V03
V07
V09
V11
V15
V08
V10
V12
V16
V05

Turbo Housing
First Simulation

Sixth Simulation / First Physical Sample
Turbo Housing
Sixth Simulation / First Physical Sample

Ninth Simulation / Intermediate Sample
Turbo Housing
Ninth Simulation / Intermediate Sample
Fourteenth Simulation / Final Sample / PPAP Run

Turbo Housing
Initial Sample

Turbo Housing Intermediate Version

Porosity

Turbo Housing Initial Sample

Shrinkage Porosity Prediction High Correlation with Physical Casting
First Casting Sample / High Fidelity Prototype
March 1st, 2013
Virtual Prototype

Turbo Housing Initial Sample

First Casting Sample / High Fidelity Prototype
March 1st, 2013
Virtual Prototype

Turbo Housing
Intermediate Sample

Turbo Housing Intermediate Sample

Porosity


Porosity Free Scale


Virtual Prototype

Intermediate Casting Sample / High Fidelity Prototype

Intermediate Casting Sample / High Fidelity Prototype
Pure Power Technologies

Confidential and Proprietary
March 1st, 2013
Virtual Prototype

Turbo Housing
Final Sample
PPAP Run
18
Turbo Housing Final Sample / PPAP Run

Porosity


Porosity


Final Casting Sample / High Fidelity Prototype

Virtual Prototype


Final Casting Sample / High Fidelity Prototype

March 1st, 2013
Virtual Prototype

Who is responsible for getting

castings out of the door faster?
Management?
Yes If they put the right tools and procedures

in place!
Sales and Marketing?

Engineering?
Production?
Yes If they get us good

castings!
Yes If they avoid trial & error and get us good

rigging that works!
Yes If they improve productivity!
Cleaning Department?
Quality?
Yes If they can speed

up!
Yes If they need to test less!
Shipping Department?
No depend on all prior

operations!

Does Simulation have an impact on?

the Quality Department?
Less defects cause less testing - speed up product flow
Less defects cause less x-ray - speed up product flow
Less defects cause less ultra sound - speed up product flow
Better castings are quicker to check!

Simulation reduces defects!
So Yes!

the Speed of the Cleaning Department?
Less defects cause less rework - speed up product flow
Less riser contact area - speeds up product work flow
Less ingate contact area - speeds up product work flow
Simulation eliminates defects, reduces riser and gate

contact areas!
So Yes!
Cost savings through scrap reduction

Original geometry and modified rigging of a steel casting
AFS 116th Metalcasting Congress

April 17-20,2012 - Columbus, OH USA
Costs and Savings for the

Original and Modified Rigging


Production?
Less defects lead to less castings poured to fill the order
increases productivity
Improved yield leads to less material poured, less energy
used, less environmental impact increases productivity
Simulation reduces defects and improves yield!
So Yes!
Energy and Cost Savings through

Scrap Reduction and Yield Improvement
Unconventional re-design of the gating systme after quality
problems with entrained slag and bubbles

Energy and Cost Savings through

Scrap Reduction and Yield Improvement
New gating system leads to a yield improvement

from 62 to 67 %
The total scrap rate fell from 17 % to 7 %
Total Cost Savings

24,000 parts/year -> US$ 500.000


the Engineering Department?
Moving trial & error into the virtual world saves money and
time in the real world speeds up new product development
Improving gating and riser systems to eliminate defects and
improve yield helps production, quality, and cleaning to be
more productive and faster with new parts and current
production
Simulation traditionally does this!
So Yes!
Simulation Supports Cost Optimization

Comparison sample castings with / without simulation
Year
2008
Number of
Samples
529
Rejects without
Simulation
29.87%
% Improvement
46.24%

Rejects with
Simulation
16.06%
%
Improvement
46.24%
Avoided
Prototype Costs
$109,500
Total Savings
Summary
Sample Savings
Reject Savings
$588,000
$204,000


Sales and Marketing?
Better communication with customers will lead to the
acceptance of design changes less trial & error to make a
part work
Better quoting will assure that castings make money and are
competitively priced assure castings fit production
Faster throughput is a key requirement of customers
differentiates good from bad foundries
Simulation helps with communication!
So Yes!
Original Geometry
Casting Weight = 459 lbs EAU = 1200 each part number

Original Gating Geometry
Mold Weight = 1675 lbs

Porosity

New Geometry
Changes were made that removed 26.4 lbs per casting or 6%

of the total weight. Current cast weight = 432.6 lbs
New Gating Geometry
Mold Weight = 1349 lbs

A savings of 326 lbs per mold
Porosity
No porosity evident in the castings

Summary
Sand/Slag Defects Greatly Reduced through
bottom filling vs. top filling.

Weight Reduced by going from thick flange to
single bosses.
Stress Load Reduced by spreading it out over
larger area with single bosses.
Porosity and Suck down Reduced/Eliminated by
reducing Modulus (thinner flange) and increased
surface area (better heat extraction).
Two-Fold Use of Simulation:
Develop New Geometry.
Cost Justification for management to make
changes
Savings
26.4lbs Weight Reduction per Casting (5.8%) - $6,331.00/year
savings in material costs
Scrap Reduced from 10.3% to 1.4% - $66,936.48/year savings
Mold Yield Increased from 58% to 64% - $66,000.00/year
savings
Weight Savings of 326lbs/mold @ 1,200 molds/year 200 tons
more capacity on a line that ran at 100%!

Savings and Cost Avoidance

Casting ran for one year with high scrap and low yield!
New Design Total 1st Year Savings:$139,867.48
Pattern Mod. + Engineering:
- $120,000.00
Cost Net Savings 1st Year:
$ 19,867.48
Potential Cost Avoidance if Simulation and New Design would have been used right
away:
Year 0: $139,867.48
Year 1: $139,867.48
Avoided Pattern Mod. + Eng.:
$120,000.00
Total: $399,734.96
Cost Avoidance is better than Cost Savings or

Cost Improvement!


Management?
Higher productivity leads to higher profits makes
management happy makes board of directors happy
Better quality castings, delivered on time, makes customers
happy differentiates a great foundry from a good foundry
Great companies attract/retain great people making the
company even more competitive
Simulation helps with all this!
Simulation is a
Get More Good Castings Shipped
Tool!
For additional information, please contact:
Christof Heisser
10 N. Martingale Road, Suite 425
847-252-1650
847-969-1003
info@magmasoft.com
www.magmasoft.com
Carlos Esparza
1401 Perkins Avenue
Waukesha, WI, 53186
262-548-1641
Carlos.Esparza@PurePowerTechnologies.com
www.purepowertechnologies.com

Would You Like To Get More Good Castings Shipped?

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Would You Like To Get More Good Castings Shipped?

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Would you like to get more

good castings shipped?

AFS 75th Wisconsin Regional Conference

Ductile Iron HighSiMo Turbo

AFS 75th Wisconsin Regional Conference

March 1st, 2013

AFS 75th Wisconsin Regional Conference

AFS 75th Wisconsin Regional Conference

AFS 75th Wisconsin Regional Conference

Sixth Simulation / First Physical Sample

Sixth Simulation / First Physical Sample

AFS 75th Wisconsin Regional Conference

Ninth Simulation / Intermediate Sample

Ninth Simulation / Intermediate Sample

Fourteenth Simulation / Final Sample / PPAP Run

AFS 75th Wisconsin Regional Conference

AFS 75th Wisconsin Regional Conference

Turbo Housing Intermediate Version

AFS 75th Wisconsin Regional Conference

Turbo Housing Initial Sample

March 1st, 2013

AFS 75th Wisconsin Regional Conference

Turbo Housing Initial Sample

March 1st, 2013

AFS 75th Wisconsin Regional Conference

AFS 75th Wisconsin Regional Conference

Turbo Housing Intermediate Sample

AFS 75th Wisconsin Regional Conference

Turbo Housing Intermediate Sample

AFS 75th Wisconsin Regional Conference

Turbo Housing Intermediate Sample

AFS 75th Wisconsin Regional Conference

Intermediate Casting Sample / High Fidelity Prototype

Turbo Housing Intermediate Sample

Pure Power Technologies

March 1st, 2013

AFS 75th Wisconsin Regional Conference

Turbo Housing Final Sample / PPAP Run

AFS 75th Wisconsin Regional Conference

Turbo Housing Final Sample / PPAP Run

AFS 75th Wisconsin Regional Conference

Turbo Housing Final Sample / PPAP Run

Final Casting Sample / High Fidelity Prototype

Pure Power Technologies

AFS 75th Wisconsin Regional Conference

Turbo Housing Final Sample / PPAP Run

Final Casting Sample / High Fidelity Prototype

Pure Power Technologies

March 1st, 2013

AFS 75th Wisconsin Regional Conference

Who is responsible for getting

Yes If they put the right tools and procedures

Sales and Marketing?

Yes If they get us good

Yes If they avoid trial & error and get us good

Yes If they can speed

Yes If they need to test less!

No depend on all prior

AFS 75th Wisconsin Regional Conference

Does Simulation have an impact on?

Better castings are quicker to check!

Does Simulation have an impact on?

Simulation eliminates defects, reduces riser and gate