Today, the market demands smaller series. As a result, large series find fewer customers, as components are needed for growing niche applications. This causes problems for Emerson‘s designers. They were used to designing for large batches. Before starting production, the foundry usually tested the component extensively with prototypes. The engineers used casting process simulation only after the production had started in order to adjust the gating system, correct problems or reduce the pouring time.
The effort for this approach increases considerably in relation to the production volume of a small series. Tests and trials drive up overall costs. The developers have to adapt to these circumstances and start simulating while they are still designing the component, even before production starts. This allows them to identify and avoid casting defects, as well as to ensure a high level of quality during development. Thus, they design a suitable gating and risering system that guarantees a robust and defect-free production.
As a systematic approach, the foundrymen decided to use MAGMASOFT® to first layout the risers and then to design the gating system, considering the best pouring time.