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Castings Simulation in Shell Moulding

07 April 2011

Perucchini says that the introduction of the foundry simulation software for the design of new castings gets many benefits: - achievement of high quality standards - best efficiency in the design analysis - reduction of the time-to-market - simplified research of innovative shapes and solutions.

The simulation software allows to visualize and monitor the proper filling of the shell forms by the liquid metal and the relevant following solidification process (1, 2). This activity helps to predict and thus avoid possible defects (such as gas porosities, shrinkage, incomplete filling) inside the casting, which could cause breaks during the working life of the component subject to mechanical stresses. To overcome these problems the Perucchini designers have developed innovative feeding systems (picture 3, casting fed by up to 6 points) that ensure the internal and external integrity of complex casting with any kind of material: nodular, vermicular, austempered and CrNi alloyed cast iron. A special version of the software allows to support the lay-out and optimisation of the casting processing for stainless, alloyed and carbon steel components. The pouring simulation strongly reduces the timing of the product development and grants a steady and controlled casting quality since the first samplings. Furthermore, improved feeding systems allow to increase the forming yield and thus to reduce the production costs.
The simulation of all new projects and the full Shell Moulding forming make Perucchini a leader in the production of high quality castings with complex geometries.

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