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CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations.

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Presentation on theme: "CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations."— Presentation transcript:

1 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 1 Flow Simulations in HPDC Process - Some Practical Case Studies A.Pari CRP (India) Private Limited

2 One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago About CRP 2

3 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Our Founder Mr. N.KUNCHITHAPATHAM Born into an agricultural family Technically qualified from a rural polytechnic Served in TANSI for 12 years Part of the first generation team exposed to die-casting in India under a joint Indo-Russian project Our Pillar of Strength and Source of Inspiration 3

4 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Organization Corporate Office Thirumudivakkam Chennai Tool Room Division Thirumudivakkam Chennai Die-casting Divisions Unit 1 Thirumudivakkam Chennai Unit 2 Gummidipoondi TN Unit 3 Perungudi Chennai JV (CTI) Gummidipoondi TN Product Division (Thirumudivakkam) Engineering Services Division (Thirumudivakkam) 4

5 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago PUMPS Oil Pumps, Water pumps, Fuel Pumps ELECTRONIC IGNITION SYSTEMS Fly Wheel Magnetos, Regulator / Rectifier units, Ignition Coils, Distributors OTHER APPLICATIONS Brakes, Turbo Chargers, Power Steering Systems, Seat Belts TRANSMISSION COMPONENTS Case Speedometer, Case Gear Shift FUEL SYSTEMS Filter Heads, Filter Bowls, Governor Cover, Fuel Rails, Carburetors AUTO ELECTRICALS Starters, Alternators, Dynamos, Ignition Coils, Small Motors, Wipers, Fog Lamps, Head Lamps ENGINE COMPONENTS Crank Case Door, Housing Oil Seals, Case Distributor, Thermostat Case, Levers, Rocker Arm Pressure Die Castings - Automobile Applications Product Ranges 5

6 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Product Ranges 6

7 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Our Major Customers 7

8 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago One Stop – End to end Supplier of High Pressure Die-Castings (HPDC) CRP has in-house facilities for HPDC Product Design Modeling Shot Design and Flow Simulations Die Design Die Manufacturing Die-Casting (HPDC) Trimming and Fettling Surface Finishing Machining ZEISS CMM & FARO Portable CMM 8

9 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago CRP -TCDC Diecastings India Private Limited CRP (INDIA) Private Limited enters into a JV with TWIN CITY DIE CASTINGS CO. To form 9

10 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Studies Application of Flow Simulation in the Die Casting Process

11 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study One PRODUCT REDESIGN 11

12 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 12 Customer Requirements Two Part Variants required from one casting Variants produced in machining stage Variant -1 Without hole Variant -2 With hole As Cast Part - Indicates Machined Surfaces Case Study 1: Product Redesign

13 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 13 Challenges? Mold is common Design constraint in gate feeding Mold parting line construction is complicated Because of part intricacy unable to provide over flows Thick sections creates shrink porosity regions Problems? Shrink porosity exposed during machining in Variant -2 Part weight unnecessarily increased due to unused hole boss in Variant -1 Case Study 1: Product Redesign

14 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 14 Flow and solidification simulations done in common model. The potential surface defects and shrink porosity locations identified. CRP communicates to the customer about shrink porosity and suggests independent molds for both variants. But customer insisted on making one mold to produce both variants. CRP made the mold During machining the Variant –2 shrink porosity is exposed as predicted by simulation Development History Case Study 1: Product Redesign

15 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 15 Decision Change by the Customer Due to the shrink porosity in Variant -2, the customer changed his decision to make independent molds for each of the variants. CRP Actions Now the variants were produced in independent molds. Case Study 1 : Product Redesign

16 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 16 Part View Variant -1 Without holeVariant -2 With hole Case Study 1: Product Redesign

17 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 17 Variant -1 Without hole Variant - 2 With hole Mold design comparison between Variant -1 to 2 Case Study 1: Product Redesign

18 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 1: Product Redesign 18 Flow Results Variant -1 Surface defects comparison between variants Flow Results Variant -2

19 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 19 Flow Results Variant -1 Surface defects comparison between variants Flow Results Variant -2 Case Study 1: Product Redesign

20 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 20 Solidification simulation comparison between variants Solidification Results Variant -1 Solidification Results Variant -2 Case Study 1: Product Redesign

21 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 21 Solidification simulation comparison between variants Solidification Results Variant -1 Solidification Results Variant -2 Case Study 1: Product Redesign

22 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 1: Product Redesign 22 Shrink porosity is eliminated in Variant -1 (without hole) Part weight also reduced Variant -1 Variant -1 Model

23 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 1: Product Redesign 23 Variant -1Variant -2 The variants were produced in independent molds.

24 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study Two RUNNER BALANCING AND OPTIMIZATION 24

25 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 25 Design Requirements Needed 4 cavities One moving slide / cavity Flow needs to be balanced Layout to be optimized Development History CRP developed the shot model with 4 cavities Uniform and balanced flow was ensured by multiple iterations

26 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 26 CRP developed the shot model Version 1, carried out the flow simulation Version-01

27 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 27 Version-01 Flow simulation Flow results are satisfactory But tool layout is too big, all the moving slides were in top side cannot be accommodated in specified DC Machine Case Study 2: Runner Balancing & Optimization

28 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 28 Version-02 2 cavities placed left and right; Moving slide is oriented left and right side Tool layout is comfortable to accommodate in specified DC Machine Case Study 2: Runner Balancing & Optimization

29 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 29 Runner entry at gate position is unbalanced Version-02 Flow simulation Case Study 2: Runner Balancing & Optimization

30 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 30 Version-03 Version-04 Version-05 Runner and over flows fine tuned

31 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 31 Flow simulations Runner and over flows fine tuned Version-03 Version-04 Version-05

32 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 32 SHOT optimized in Version 10 Case Study 2: Runner Balancing & Optimization

33 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 33 Gate Entry optimized in Version 10

34 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 34 SHOT optimized in Version 10

35 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 2: Runner Balancing & Optimization 35 Solidification simulation

36 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 36 Potential shrink porosity regions identified in solidification simulation There is no machining requirement near shrink porosity regions Case Study 2: Runner Balancing & Optimization

37 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 37 First time right – SHOT Case Study 2: Runner Balancing & Optimization

38 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study Three RE-ENGINEERING 38

39 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 3: RE-ENGINEERING 39 Customer Requirements Eliminate fallouts Part to be manufactured in conventional PDC process. Part weight to be minimized without compromise of its requirements Existing Part Previously it was manufactured through non- conventional PDC process Fallouts: 50% leakers and salvage rate of around only 50% after impregnation. >5% fallout due to exposed porosity

40 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 40 CRPs Observations Part thickness variation observed in many places Sections to be re-engineered to be uniform Excess machining stocks observed Gate area too big in existing part Case Study 3: RE-ENGINEERING

41 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 3: RE-ENGINEERING 41 Development History New model developed Minimum wall thickness 5.0 to be considered Where ever possible thick sections to be reduced to maintain 5.0 thickness 0.50 mm uniform machining stock per side to be maintained New gate entry positions selected Flow and solidification simulations done by CRP in PDC process Simulations results convinced to go for conventional PDC process

42 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 42 Surface defect concentration simulation Case Study 3: RE-ENGINEERING

43 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago 43 Solidification simulation The potential shrink porosity regions identified and ensured that they are away from the machining area and not exposed during the machining process Case Study 3: RE-ENGINEERING

44 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago Case Study 3: RE-ENGINEERING 44 Customer Approval All the suggestions given by CRP were approved after due scrutiny and customer released the revised drawing Machined Part Fallout due to exposed porosity NIL Leakers NIL Impregnation Requirement ELIMINATED

45 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago CONCLUSION The objective of this presentation is to rekindle, energize and encourage the fellow die-casting fraternity to use more and more simulation techniques. The manufacturing sector is undergoing a serious challenge amidst the global economic slowdown; it is high time Diecasters looks inward to find lasting solutions and simulations are the key. The objective of this presentation is to rekindle, energize and encourage the fellow die-casting fraternity to use more and more simulation techniques. The manufacturing sector is undergoing a serious challenge amidst the global economic slowdown; it is high time Diecasters looks inward to find lasting solutions and simulations are the key.

46 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success Tool Room Division Flow Simulations in HPDC Process - Some Practical Case Studies 2013 FLOW-3D World Users Conference, Chicago ACKNOWLEDGMENTS A Special Thanks to Flow Science and the FLOW-3D Team For its efforts in terms of Encouraging knowledge sharing Motivation for research and development And giving this opportunity Thank You -A.Pari. Director CRP (India) Private Limited CRP-TCDC Die Castings India Private Limited The author would like to thank all his colleagues at CRP and CTI for their help and support


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