The first three case studies are pertaining to a very critical part - a crank case used in an automobile compressor application. During the production process, the die was found to wear very frequently resulting in high rejection rates

This case is a continuation of the previous one, in terms of the design improvements as suggested by CRP. Upon close examination of the design and the part drawing, it was found that the general radius was called for as 1.6 mm, whereas in the design

This case is also a continuation of the previous two, in terms of cause and effect correlation and acceptance criteria. Porosity was always an issue since the beginning of the development of this part, as it is needed to be pressure tight.

Reducing the cost is the need of the hour, and the design simplification is one of the effective means. This case is an example of the same where as the customer requirements in terms of volumes have increased and adding capacity at this juncture should be the last option. Hence we explored the possibility of […]

Certain part designs will remain a challenge to be pro­duced, and it evokes a lot of effort from the designer's point of view. One such case is considered here, wherein the simulation results helped in persuading the customer to accept the alternate designs in order to make the parts much easier to produce, and to […]

It is always desirable to fix acceptance criteria for porosity at the beginning of a product life cycle. But most of the time it is difficult to implement, as it is not easy to estimate and fix the extent and locations of the defects. Here is one such case where the simulation results in correlation […]

Everything around us changes rapidly and outside-the-box thinking is the order of the day. Lateral thinking by the designers will evoke simple solutions, even for complex problems. This case is a typical example of that. Using a chill is a common concept to avoid/shift poros­ity in gravity casting. One of the automotive application parts, an […]