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
• 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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