This case study is an example of an approach towards the application of flow and solidification simulations to cor­relate the location and inevitability of shrinkage porosity. Analysis of Results Flow analysis followed

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 […]

This part was transferred from another source by the customer and was intended for the export market. The initial batches were supplied in two variants. The first variant failed before and after assembly at customer end

It is a common practice to make dies with interchange­ able inserts and core pins to produce different variants from a same die to overcome the cost implications. This is more so in the case of low volume parts where die cost per piece is very high.

Again this case study was also based on a group of four variants of similar parts developed by the customer else­ where and transferred to CRP. They are cylinder heads of the compressors and needed to be 100% leak tested.

Several instances of repeated failures of the die casting process resulted in high rejects, premature failure/short life of the die, etc., which are yet to be resolved. This case study is an example of one such die for a part, a filter head of a fuel filtering system

Machining of the casting is one of the neglected areas as far simulation is concerned, though a lot of tools have been available for a long time. This case study describes the effective use of the same in the real life situation

Having realized the potential of the machining optimiza­tion tool, CRP has decided to seamlessly integrate it into the quoting system for accurate machining conceptualiza­tion, precise cycle time computations