The Allied team went to work optimizing the gating and runner design to reduce the entrapped air pockets and achieve a more uniform frontal flow. Numerous trapped air pockets were indicated during the fill of the casting. The simulation results showed that the filling pattern was not optimal. When the die arrived at Aallied Die Casting, the team was able to analyze the runner and gating system using MAGMASOFT. Aallied Die Casting (Rutherfordton, NC), a division of RCM Industries, selected MAGMASOFT casting simulation technology to meet this challenge. Due to the high volume of the casting, a solution was needed to reduce associated costs. The result of this was that the customer needed to leak test 100% of the castings those that failed leak testing were impregnated. The Aallied team reviews the final simulation of the optimized casting process set-up.Īn automotive transfer case housing, which is used on a full-sized four wheel drive truck, was experiencing a fallout rate of over 7% - 70,000 parts per million (PPM) - at the customer, prior to its arrival at Aallied Die Casting. Aallied Die Casting performs none of the secondary machining.
Magmasoft centrifugal casting pdf#
Engineering design of centrifugal casting machine: PDF By simulation of the transfer tool showed that the filling pattern trapped excessive amounts of air during filling.Įxtensive machining is performed at the customer's facility.More maintenance and skilled operator is required.It is not suitable for manufacturing any type of material.The centrifugal casting cast only symmetrical shapes therefore Limited design can be cast from this process.The size of components we manufacture here is limited.More machining is required when we manufacture components other than cylindrical and there is more chance of making the process more costly.When we manufacture other than cylindrical structure there is a loss in structural and purity benefit. It is good for manufacturing only cylindrical structures.When we manufacture the small diameter pipe and if some impurities come in the internal diameter from this process it is very hard to remove which is a major disadvantage of centrifugal casting.In centrifugal casting, the temperature distribution and solidification time is difficult to determine.Inclusions and impurities of the casting process are lighter.The component we manufacture from the centrifugal casting process has high mechanical properties and dense metal.The centrifugal casting process can be used for mass production.For casting hollow shapes like tubes and other components we do not require cores.The runner and gating system in this casting process is not there.This casting process can produce components with intricate geometries at a lower cost.By centrifugal casting, a thin wall cylinder can be easily manufactured which is a very good advantage.The impurities like oxide or any other slag particles are being segregated at one point and that can be easily removed from there.The energy can be saved as it requires a lower pouring temperature.The centrifugal casting process has lower casting defects because of uniform solidification.We also make Clutch plates Paper making rollers from this casting process.This process is also used when a uniform grain structure is required.It is also used to create any parts whose shapes are symmetrical about an axis.The centrifugal casting process used in the electronic industry for manufacturing switchgear components.It is also used to manufacture carriage wheels of railway and bearings.This casting process widely used in aircraft industries for casting flanges, compressors, and rings.This casting process used in the automobile industry for various products manufacturing like a piston, cylinder liners, and so on.Centrifugal casting is used to cast hollow cylindrical metal pipes.