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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 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 Slide 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 Slide 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 1948-2005 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 Slide 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 - 600 044 Tool Room Division Thirumudivakkam Chennai - 600 044 Die-casting Divisions Unit 1 Thirumudivakkam Chennai - 600 044 Unit 2 Gummidipoondi TN - 601 201 Unit 3 Perungudi Chennai - 600 096 JV (CTI) Gummidipoondi TN - 601 201 Product Division (Thirumudivakkam) Engineering Services Division (Thirumudivakkam) 4 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 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 Slide 23 CRP (India) Private Limited One Stop Solution for Pressure Die Casting Products - Casting Excellence - Molding Success

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