crp (india) private limited one stop solution for pressure die casting products - casting excellence...

CRP (India) Private Limited

One Stop Solution for Pressure Die Casting Products- Casting Excellence- Molding Success

Tool Room DivisionF l o w S i m u l a t i o n s i n H P D C P r o c e s s - S o m e P r a c t i c a l C a s e S t u d i e s

2013 FLOW-3D World Users Conference, Chicago

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Flow Simulations in

HPDC Process - Some Practical Case Studies

A.Pari






About CRP

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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

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Organization

Corporate Office

ThirumudivakkamChennai - 600 044

Tool Room Division


Die-casting Divisions

Unit 1


Unit 2

GummidipoondiTN - 601 201

Unit 3

PerungudiChennai - 600 096

JV (CTI)

Gummidipoondi

TN - 601 201

Product Division

(Thirumudivakkam)

Engineering Services Division

(Thirumudivakkam)

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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

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Product Ranges

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Our Major Customers

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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

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CRP -TCDC Diecastings India Private Limited

CRP (INDIA) Private Limited enters into a JV withTWIN CITY DIE CASTINGS CO.

To form

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Case StudiesApplication of Flow Simulation

in the Die Casting Process





Case Study One

PRODUCT REDESIGN

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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





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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






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• 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






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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





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Part ViewVariant -1 Without hole Variant -2 With hole






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Variant -1 Without hole Variant - 2 With hole

Mold design comparison between Variant -1 to 2Case Study 1: Product Redesign




2013 FLOW-3D World Users Conference, ChicagoCase Study 1: Product Redesign

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Flow Results Variant -1

Surface defects comparison between variants






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Surface defects comparison between variants







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Solidification simulation comparison between variants

Solidification Results Variant -1 Solidification Results Variant -2






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Solidification simulation comparison between variants

Solidification Results Variant -1 Solidification Results Variant -2






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• Shrink porosity is eliminated in Variant -1 (without hole)

• Part weight also reduced

Variant -1 Variant -1 Model





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Variant -1 Variant -2

• The variants were produced in independent molds.





Case Study Two

RUNNER BALANCING AND

OPTIMIZATION

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Case Study 2: Runner Balancing & Optimization

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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






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• CRP developed the shot model Version 1, carried out the flow simulation

Version-01





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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






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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






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Runner entry at gate position is unbalanced

Version-02 Flow simulation







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Version-03 Version-04

Version-05

Runner and over flows fine tuned






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Flow simulations

Runner and over flows fine tuned

Version-03 Version-04

Version-05





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SHOT optimized in Version 10







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Gate Entry optimized in Version 10






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SHOT optimized in Version 10






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Solidification simulation





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• Potential shrink porosity regions identified in solidification simulation

• There is no machining requirement near shrink porosity regions






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First time right – SHOT






Case Study Three

RE-ENGINEERING

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2013 FLOW-3D World Users Conference, ChicagoCase Study 3: RE-ENGINEERING

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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





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CRP’s 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





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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





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Surface defect concentration simulation






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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






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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

LeakersNIL

Impregnation RequirementELIMINATED





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.





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 LimitedCRP-TCDC Die Castings India Private Limited

[email protected]

The author would like to thank all his colleagues at CRP and CTI for their help and support

crp (india) private limited one stop solution for pressure die casting products - casting excellence...

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