case-lecture kon-80.3121 construction design of cast ... · 2 . 20.11.2015. case-lecture 3.2.2016...

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Case-lecture 3.2.2016

Kon-80.3121 CONSTRUCTION DESIGN OF CAST COMPONENTS Jesse Salmi – Product Development Engineer – Componenta

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Background

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• Jesse Salmi

• Jesse.salmi@componenta.com

• Product Development Engineer

• Education:

• 2004-2010 MSc. (Tech) TTY

Materials Engineering – Metal

Materials

• 2013-present – MSc (Econ) UTA

– Corporate Law – Ongoing

studies

• Career

• 2008-2009 – International trainee program trainee

• 2009 – Master thesis “Solution Strengthened Ferritic Ductile Iron: Foundry Process, Machinability And Tool Wear”

• 2010-2011 – Process Engineer (Machine shop)

• 2011 – Product Engineer (Machine shop)

• 2012-present – Product Development Engineer (Casting)

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COMPONENTA – WE ARE ONE OF THE LARGEST

cast component suppliers in Europe

Net sales (2014) Personnel approx. Iron foundry production

capacity tons/year

495M€ 4,200 320,000

Machining hours/year 860,000

Listed in NASDAQ OMX

Helsinki

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NET SALES 308 MEUR 80 MEUR 122 MEUR

PERSONNEL 2,750 830 400

PRODUCTION

CAPACITY 320,000 tons/year 25,300 tons/year

860,000 machining

hours/year

PRODUCTION

UNITS

Turkey 160,000

Netherlands 92,000

Finland 68,000

Turkey

Turkey 430,000

Sweden 350,000

Finland 80,000

Foundry division Aluminium division Machine shop division

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OUR DIVERSE PRODUCTION network ensures that quality is achieved at a competitive price

Foundry division

Aluminium division

Machine shop division

Foundry division Aluminium division Machine shop division

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OUR BROAD CUSTOMER BASE supports stability and innovation

15%

Automotive

17%

Agricultural Machinery

18%

Machine Building

19%

Construction and Mining

31%

Heavy Trucks

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Heavy Trucks Construction and Mining

Machine Building

Agricultural

Machinery

Automotive

33% 17% 19% 14% 17%

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We serve our customers by combining A GLOBAL NETWORK WITH LOCAL PRESENCE

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OUR NETWORK IS OPTIMIZED to provide expertise and cost efficiency to our customers everywhere

Personnel by country

Turkey 61%

Finland 16%

The Netherlands 13%

Sweden 10%

Sales by market area

Germany 21% Sweden 18% Turkey 12%

UK 9% Finland 8% Benelux 8%

Italy 6% France 6% USA 5%

Other Europe 4% Other countries 2%

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OUR FOUNDRY DIVISION offers a wide range of iron casting capabilities

Iron casting capabilities

Big lines 34% Small lines 22%

Medium lines 13% Special big line 11%

Disa lines 11% Furan lines 9%

50 100 150 200 250 300 350 400 450 500 5,000 kg

GJS, GJL, ADI, SSF

GJS, GJL, ADI, SSF

GJS, GJL,

SSF

GJL

GJS

SSF

GJS, GJL, SSF

Disa lines

Small & medium lines

Big lines

Special big line

Component weight

Furan lines

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We have served our customers for

CLOSE TO 100 YEARS

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Good quality starts with

GREAT ENGINEERING

• Our engineering consists of

• Research & Development

• Product development engineering

• NPI project engineering

• Production engineering

• Project management

• We strive to constantly raise the bar by developing

and improving our offering to our customer

• Growing the size and know-how of our engineering

department is one of our strategic initiatives

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We offer a wide range of

ENGINEERING SERVICES

Project Management

• Dedicated Project Management Office

• Clear project organization

• Supply chain management

• Know-how project execution

• Process oriented project approach

• Product Development Contract

• Continuous transparency

Technical features / support

• Supply chain know-how / expertise (Foundry / Machining etc.)

• Foundry Simulations (MAGMA soft)

• Filling / Solidification

• Residual stresses

• FEA analysis

• Static, dynamic & fatigue analysis

• 3D CAD

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Molding

methods in

Componenta

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• Molding methods in Componenta

• HWS (Horizontal molding)

• Disa (Vertical molding)

• Hand molding

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Hand molding

– Large castings (0,2-5 ton), complex cores

– Exothermic feeders common and chills

– Freedom of gating system with ceramic

tubing

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DISA-molding

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HWS-molding

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• Tuorehiekka on saven tapaista

saa lujuutensa puristuksen avulla

• Hiekka puristetaan mallia vasten

josta syntyy muotinpuoliskot

• Edellisen seurauksena tarvitaan

jako muotinpuoliskoihin (jakotaso)

sekä hellitykset jotta mallilevy

irtoaa hiekkamuotista

HWS-molding

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Case - Delimbing

Knives

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• Design often almost fixed before suppliers are involved

• No comprehensive redesign possible anymore for other parties in Supply

chain therefore we are not achieving max. feasibility

• Cost level unsure till the end of the project

• No optimum for all parties in supply chain

Conventional engineering – characteristics (in practice)

Conventional vs product development

engineering

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Design Engineer

Machinist

FEA

Design Foundry

Assembling

Feasible for whole supply chain Meet all functional and quality requirements

Lowest costs Reduce time to market

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Conventional Engineering

Design/Engineering

FEA

Foundry Simulations

t=0 Design Freeze

Casting Design

Start Tooling

Design/Engineering

FEA

Foundry Simulations

Casting Design

Start Tooling

Product Development Engineering Design Freeze

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Objective:

Redesign of welded knife to cast design

Main Targets:

• Stresses : As low as possible

• Weight : Same or lighter than

current design

• Costs : Cost reduction to

current design

Target lead time

Development within 2 months

1. Design Kick - off

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1. Design Kick - off

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3. Product Development

CAD

Cost Analysis

Foundry

simulation

FEA

Multiple

iterations

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3. Product Development

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Achievements

• Development within 2 Months (design), 4 months (first samples

delivered as machined)

• Weight not raised (stress minimization was priority)

• Stress level 630 Mpa, 10 % under target 700 Mpa. (safety factor

included)

• Cost saving 40%

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• Testing bench results :

110 % longer durability in fatigue test

Achievements

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• Maximum added value for Customers and suppliers

• Shorter lead time Time to Market

• Optimum design in terms of:

o Functionality

o Lowest overall costs

o Casting design

o Machining design

• No surprises at the end

Benefits

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• Early involvement

• Full understanding of customers demands and requirements

• Process/ project oriented approach

• Product Development Contract

• Clear internal and external project organisation and communication

Conditions for succesful project

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Comparison between cast geometries

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Comparison between cast geometries

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Comparison between cast geometries

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Pattern

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Core assembly

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© Componenta

3D Printing Prototyping

at

Componenta Finland

Case Example

Case study Toni Siik Product Development Engineer

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Bracket Prototypes

• The customer needed two pairs of

prototypes quickly for concept

machines.

• The design of the castings was not

finalized.

• Componenta was chosen to be the

design partner for the parts.

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Realization of the prototypes

• Lead time for the prototypes was only 4 weeks from the order.

• An extremely short leadtime + unfinished design + low number of required pieces

Making tooling for the parts was not the ideal solution as the parts will change during their next steps of development

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3D printing of the sand molds

was chosen as the production

method

No tooling required

Undercut features

were no problem

Short lead time

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3D Printing of Sand Molds

Benefits

• Relatively fast for a few pieces

• Freedom of shapes

• Undercuts are no problem for the process

• No tooling needed

• Changes to geometry will not cost any more than the initial pieces

• Each piece can be different at the same printing cost

Drawbacks

• Expensive for large amounts of pieces

• The technology is relatively new and

there are a limited number of

manufacturers for the machines.

• Slow when producing larger amounts of pieces

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3D printing of sand is quite a new innovation which allows production of sand

molds directly from 3D files without tooling

For complex pieces with lots of cores 3D printing can provide a very

cost effective way to produce a few prototypes

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Printing process

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Complete freedom of shapes

Relatively fast

No need for tooling

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Design of the casting method

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Casting system verification

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Mold design

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Pictures from the project

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Pictures from the project

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Pictures from the project

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End Result

• The castings were done within 8 days

from the order

• Machining was finished within 15 days

from the order

• The castings were delivered to the

customer within 25 days from the order

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Current Capabilities

• Currently it is possible to get 3D prints of molds and cores

up to 1100x600x500 in size locally from a Finnish

supplier.

• Larger prints possible from a German supplier

• Currently the 3D prints are being poured at our Karkkila

foundry or in Iisalmi foundry.

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Toni Siik

Product Development

Engineer

Case - Housing for Oil Lub.

Cooler

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Changes to the flange geometry

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Modification 1.1: Change channel geometries to reduce number of cores

Modification 1.2: Fill in back-drafted features of the flange to reduce need for cores or loose-pieces in pattern

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Changes to the internal and main geometry

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Modification 2.1: Change channel geometries to reduce number of cores

Modification 2.2: Fill in back-drafted features of the flange to reduce need for cores or loose-pieces in pattern

Modification 2.3: Move walls to keep wall-thicknesses constant

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General wall-thickness increase

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The current geometry has shown a

tendency for cracking and leaking.

Under analysis the nominal wall-

thicknesses are extremely thin and thus

contribute to the challenges. Increasing

these wall-thicknesses will improve the

soundness of the castings and provide

better quality.

Proposal:

Modification 3.1

External walls: increase minimum wall-thickness to 14 mm Walls from the internal channels to the exterior of the

casting.

Modification 3.2

Internal walls: increase minimum wall-thickness to 12 mm Walls between the channels.

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Porosity indication on the machined surface

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Porosities of 1% or larger shown as red

As quite a lot of material is

removed from the inside in

the machining operations

it is quite probable that the

machined surface will

have some porosity

defects. These defects will

be extremely challenging

to remove completely.

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Toni Siik

Product Development

Engineer

Case - Stator

Housing

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External Geometry Changes

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The external geometry of the

casting had to be modified so

that the external shapes had a

draft to 4 sides. Without these

drafts it would have been

impossible to produce the

external shapes to the casting.

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Internal Geometry Changes

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The original design of the casting

had no drafts on the inside to

allow for molding with either the

mold or a core. The design was

changed that the middle section

of the ribs is produced with a

core that has drafts up and down,

and the ends of the ribs are

produced with the mold.

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Production Method Feeding Method

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In order to produce a sound casting

several feeders were needed to

feed the top part of the casting.

When possible the number of mass

centers should be minimized and

connected together to simplify the

feeding system.

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Production Method Core Package

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In order to produce the shapes

of the casting a total of 5 cores

were needed together with the

changes in the geometry. The

external shapes of the casting

were produced with 4 segments

and the main part of the ribs

with one central core.

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Core package assembly

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The core package is assembled

in the mold in several steps. The

external cores have been

designed so that the sides need

to be placed first with the ends

following them.

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Final Mould Tooling

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The tooling to produce the molds

comes as an end product when

the manufacturing concept

(cores, gating- and feeding-

system) has been finalized.

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Examples of complex castings 1/2

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Examples of complex castings 2/2

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Stator Housing Stress simulations

Case

Jesse Salmi Product Development Engineer

4.12.2014

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Casting system

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Simulation information

• Magmasoft 5

• Simulated 1 cavity with filling time 25s

• 10,7M cell with 600 000 cavity cells

• Machining step is simulated and

material removed after cooling the part

to 20°

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Temperature

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After Filling After solidification

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Yield Stress

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Casting Machined

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Max Principal Total Strain

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Casting Machined

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Total Displacement

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Casting Machined

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Comments

• Total Displacement shows that

after machining the part has

tendency to distort to ellipse

shape.

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Total Displacement after machining

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Things to remember

• Involve the foundry as early as possible during the design, especially if

designing complex casting

• Don’t try to make 100% sound casting

• Remember uniform wall thickness

• Think about drafts in early stage of design

• Choose parting surface early and consult foundry about it

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