In recent decades, materials and manufacturing technologies have advanced significantly. Today, casting alloys are available for virtually every application, together with highly efficient moulding and casting processes. Nevertheless, quality problems still occur in the procurement of cast components, often resulting in scrap, delivery delays and additional costs.
Many of these problems can be avoided at an early stage during component development. A casting-friendly design provides the basis for reliable and cost-effective production. We consider not only the casting process itself, but the entire manufacturing process – from moulding and feeding to shakeout, core removal, cleaning and finishing.
Optimising a component for moulding includes, for example, reducing or eliminating cores, optimising the parting line, simplifying pattern withdrawal and avoiding unnecessary undercuts. Designing the component with cleaning and finishing in mind can also significantly reduce the effort required for shakeout, core removal, grinding and subsequent finishing operations.
Modern simulation methods are available for analysing the casting process. By simulating mould filling and solidification, potential casting defects can be identified before production begins, allowing targeted improvements to the component design or manufacturing process. Where required, thermal stresses and the risk of distortion can also be analysed.