Role of Atlantis in Casting Industry

Complete Tool Design with Simulation

•3D Model Creation

•Pattern Creation & Extraction

•Core Box Creation

•Match Plate Design

•2D Detailing for Core box & Match Plate Judgment, Solidification &
Flow simulation
 Design Process Flow Chart

CUSTOMER
CLARIFICATION

PART QUALITY
ANALYSIS
MODELING CHECKING

FINAL
TOOL DESIGN
INSPECTION

MANUFACTURING PROCESS
 Tool Design Process

3D model Machined
(casting) Model

Design 1. Surrogate Data

Reviews 2. No. of cores
3. Core & Pattern Parting

Manufacturing

Core Core Core Box

Extracted Split Design

Drag & cope Drag & Cope Match Plate

Mould Pattern
 Achievements

• Component: Manifold
• Software: Pro/E
• Time: Modeling 200Hrs
• Task: Parametric Modeling using Pro/E,
Casting Design & Associative Drawings

• Savings:60%
 Achievements

• Component: Turbine Housing

• Software: Pro\E
• Time: 12hrs
• Task:Parametric Modeling using Pro/E,
Casting Design & Associative Drawings
• Savings:60% Compare to earlier legacy
system
Important Castings project
handled by Atlantis
 Fundamentals of Casting

¾Casting:
It is a process in which molten metal poured into a mould and allows it to
solidify to take the shape of the mould.

Cope mould

Drag mould
 Fundamentals of Casting

¾Core:
A core is the mass of dry sand to obtain the cavity in the casting, which is
not possible to achieve by means mould.

Cut section

Casting

Core
 Fundamentals of Casting

¾Core print:
It is added to the core in order to place and locate the cores in
the mould. The shape and size depends on the individual core.

Core

This print is going to

locate the core in the
mould.

These areas only

the print is going to
rest on the mould
 Fundamentals of Casting

¾ Allowance:
Allowance are introduce in order to produce the proper size and
shape. Here there is no definite mathematical rule to predict
allowance. This is determined on trail and error basis
Types of allowance:
1. Shrinkage allowance
2. Draft allowance
3. Machining allowance

Shrinkage allowance:
Major factor for Shrinkage is
• When molten metal changes from liquid to solid, due to it
material property it will contract.
• Because of sand elastic properties the mould will shrink while
removing pattern from mould box.
 Fundamentals of Casting

¾Draft allowance:
When pattern is drawn out from a mould, the tendency to tear away the edges of the
mould in contact with the pattern is greatly decreases, if the surface of the pattern are
given slightly taper known as draft.

Mould Mould
box box Mould
box

Pattern Pattern
Pattern

Pattern will not come out Mould face will tear drastically Pattern will remove smoothly
because o f negative draft because the point of contact because of draft.
called under cut is more

Machining allowance:
In casting model those faces which are going to mate with other part has to be
machined., These faces are represented by some machining symbols.The marks
indicates that additional metal must be provided to these faces so that some
material will be available after machining.
 Fundamentals of Casting

¾Pattern:
It is defined as a extract replica of the model,constructed in such a way that
it can be used for forming an impression in damp sand.
Upper half of the mould box Cope mould Cope pattern
Lower half of the mould box Drag mould Drag pattern

Core
Casting
print.
portion
 Fundamentals of Casting

¾General concept to decide cope or drag:

Larger casting portion should accommodate in drag because mould sand has
greater strength in compression than tension.
Cast model

Cope

Cope

This portion will

break under
tension.
Core

Drag
Core Compressive force will
Drag act, so it will never fail.
Wrong

Right
 Fundamentals of Casting

Match plate:
It is a standard plate where one or more number of patterns is mounted on it along with
the gating system.

Cope match plate Drag match plate

 Metal Flow

JUDGMENT ANALYSIS

•Take model and do L0. Analysis.

• Based on results identify Hot Spots and calculate critical Modulus.
 Metal Flow

SOLIDIFICATION ANALYSIS

•Calculate riser size, notch size as per Standards.

•Fix riser location.
•Conduct L1. Analysis
 Metal Flow

FLOW SIMULATION ANALYSIS

• Conduct flow simulation Analysis.

• Release Gating drawing.