DFM Analysis for Casting Part
Geo-Designer offer a new method to study the part geometry in 3D iso-surface mode with flexible transparently, it is similar the x-ray and CT method in industrial. Geo-Designer introduced MDI (Mass Distribution Index) and HDI (Heat Distribution Index) for part analysis and evaluation.
MDI could be used to check the heavy mass distribution of the casting part, where is easy to cause the hot spots and shrinkage porosity during the casting process. For a product design engineer, you should try to avoid big MDI on the part.
During the manufacturing phase, the MDI result could be used directly for inner gate design, riser and feeder design, cooling channel layout and hot spot prediction.
For die casting and permanent mould casting, the slider number and complex level is an important factor of the die set cost. Geo-Designer can perform slider checking for casting part to help slider design. Simply define the plug direction or opening direction and the partition plan, then the system will calculate the others. More ever, the surface of ‘Slider Zone’ also can be exported to CAD system in STL file format to guide the slider design in 3D CAD system.
Evaluate the design plan of casting system
The MDI information also can guide the gating system design. For example, the following part was used for communication device, due to the heavy MDI on the contact shaft, gas entrapment and shrinkage porosity will existed there, and the gas escapement will break the coating layer in sliver after a couple of months and damage the whole system. The first gating was complex but can not solver the gas problem and shrinkage problem, the part yield ratio was only 67.1%. After checking the MDI in Geo-Designer and understanding well of the geometry of the part, then changed the gating system to the later one, and using the 3rd phase pressure to reduce the shrinkage porosity, then the yield ratio of the part has been increased to 92%.
Other analysis functions
The other functions could be provided by Geo-Designer for part analysis, such as
- Ejection force distribution and evaluations
- Draft angle checking and undercut checking
- Fillet radius checking
- Thin wall thickness checking
- General part information, such as mass, volume, project area and thermal modulus