SysMOD – Advanced design of filling and solidification systems for castings manufacturing
The SysMOD methodology integrates the use of physics-based modelers, such as PROCAST and QUICKCAST, for manufacturing processes for cast components.
This methodology has significant application maturity primarily to cast steels and investment casting manufacturing process, but is also applicable to iron and aluminum casting.
SysMOD belongs to the advanced simulation capabilities and portfolio of the AZTERLAN team for the development and optimization of materials and manufacturing processes.
This first stage involves understanding the characteristics of the part with regard to mass distribution, establishing the position and sizing of the feeding elements applying rules for volume, modulus, and feed distance. This design will be validated through the interpretation of robust criteria such as the remaining solid fraction and the Niyama criterion.
Once the specific masses of the part to be fed have been defined, the areas of the part through which the filling will be carried out are identified. This stage is aimed at ensuring complete filling of the part, reducing the generation of inclusions, optimimizing the extraction of air and gases generated, and optimizing the overall feeding process by improving its performance (hot risers) and ensuring components soundness and quality.
Manufacture process is monitored and controlled, adjusting process conditions when it comes to key variables such as temperatures, times, and metallurgical quality to achieve optimal results regarding production, process sustainability, product quality. Most appropriate adjustments are proposed.
AZTERLAN also collaborates on the development of a specific load sheet for companies with optimal design criteria to ensure best pattern yield and product quality in terms of internal and external defects and mechanical properties and provides workforce-training for a robust application.