Uzwil, Switzerland-October 26, 2004-Jobwerx News-The close teamwork between Buhler engineers and customers makes computer casting simulations a very useful tool in die casting: Simulations allow parts to be developed within a shorter time and dies to be designed with higher precision.

Cast components are expected to satisfy ever-higher requirements. Their development is increasingly reaching the feasibility limits of die casting. As a result, to survive in the marketplace in the long term, providers must use calculations and simulations at an early stage in the development process. The Buhler Die Casting Division gives customers the necessary competitive edge in all areas of die casting by offering them computer simulation services and the correct interpretation of the simulation results.

Different opinions are desirable

Success can only be achieved by an entire simulation team, since individuals on their own are unable to perform simulations and especially to evaluate them. The accumulated experience of team members involved in the analysis is also an invaluable asset. To design successful dies, the Die Casting Division relies on specialists from the fields of process technology, die-making, metallurgy, and simulation. In the ideal case, the team will also be able to influence the geometry of the component to be cast. Different opinions are desirable in team discussions, as nobody has a total view of things and minds must be joined to arrive at new insights.

Should the team members fail to agree on a particular solution, Buhler will conduct variant studies. This just a position of different solutions reveals the useful ones. But the others are just as valuable, since they add to the accumulated experience of the team members.

What is the use of simulations?

Ideally, calculations should start at the earliest stage possible in the die development process, for changes become increasingly difficult to make as development work progresses.

What information is expected of a casting simulation?

Many customers need support in calculating the die filling and solidification process or in connection with simulations to find out what happens inside the shot sleeve. The simulation programs applied by Buhler provide an answer to a large number of casting related questions. It is also possible, on the basis of the temperature fields in the cast components, to obtain indications of casting distortion problems. Casting simulations provide the Buhler team with valuable information on die design. By optimizing the design of dies on the basis of this information, costs can be reduced and time can be saved when starting volume production. During this phase, each day available for smooth production will contribute to the financial success of the project. Computer simulations are therefore a valuable tool for speeding up the development of parts and producing them with high precision. The simulation team also offers consulting on feasibility during the initial phase.

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