Optimizing Investment Casted Parts with Simulation and 3D-Printing
Investment casting is a valued manufacturing process known for its ability to produce detailed components with accuracy, repeatability, and in a variety of different metals, waxes, and high-performance alloys.
Producing high-quality casted components is less prone to common design errors when a simulation-driven approach is used, leading to easier, more accurate analysis and optimization during the design phase.
From Know How to Know Why! - Digital Twin Design Process opening new horizons for Investment Casting
Development based on experience often means that you know what happens, but you don‘t know why! The use of Digital Twins in development helps convert empirical knowledge into physical. This creates a valid basis for optimization and caters the need for rising performance, lightweight or cost requirements.
Watch the webinar recording "From Know How to Know Why!" - Digital Twin Design Process opening new horizons for Investment Casting presented jointly with Feinguss Blank, one of the leading investment casting foundries in Europe and the EICF.
In this webinar recording you will learn how Feinguss Blank applies smart cast processes to address development challenges. The presentation will:
- demonstrate the application of simulation-driven design and additive manufacturing to drive next generation lightweight designs through an investment casting process.
- show an integrated workflow on simulation-driven-design and manufacturability, to obtain lightweight parts in a single environment.
- feature how to apply this digital twin platform for investment casting, sand-casting and within additive manufacturing or hybrid manufacturing processes.
Using Altair Software for Manufacturing
Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes. Users can validate designs early in the manufacturing process with the simplicity and affordability of the simulation software, as well as use optimization technology with specific manufacturing constraints to design better, more efficient products.
Learn more at altair.com/manufacturing-applications.
Optimization-enabled Structural and Multiphysics Analysis
Simulation-driven design powered by topology optimization was created by OptiStruct over two decades ago. Its success has changed the CAE/CAD industry as today all vendors have embraced this trend.
Altair Inspire Cast - Casting Simulation
Altair Inspire Cast is a fast, easy, accurate and affordable casting simulation environment focused on creating high quality components with increased profitability through a highly intuitive user experience. In this short video, we'll demostrate a typical setup workflow.
Driving Design from Concept to Manufacturing with Inspire
Altair Inspire has rapidly advanced from a topology optimization tool for designers to a design environment spanning industrial design, structural simulation and optimization, motion analysis and manufacturing simulation.
Altair for Manufacturing Applications
Altair offers a unique set of simulation tools to evaluate product feasibility, optimize the manufacturing process, and run virtual try-outs for many traditional, subtractive, and additive manufacturing processes.e
Training - Simulation Driven Design & Manufacturing For Casting Components Using Altair Inspire Cast & Structure
Simulation Driven Design & Manufacturing For Casting Components Using Altair Inspire Cast & Structure
Altair Inspire Cast – Filters for Gravity Casting
Filter is one of the crucial components of filling system in Castings used for multiple purpose as:
• Maintain metal flow at gate.
• Avoid turbulent behavior of liquid metal during filling.
• Retain impurities, foam and slag from the metal.
• To avoid sudden impact of metal in the cavity due to head height.
Tips & Tricks
Altair Inspire Cast Overview Video
Altair Inspire Cast software is a fast, easy, accurate and affordable casting simulation environment focused on creating high quality components with increased profitability through a highly intuitive user experience. It is the only tool that caters to beginners and experts alike, from product designers to foundry engineers.
Product Overview Videos
Designing for Profitable Casting (South African Case Study)
Several prototype castings, scrap material and low quality castings cost foundries valuable time and money. Simulation and non-destructive testing offers technology to reduce the time from CAD concept to successful casting, and helps to minimise typical loss drivers in casting profitability.
Nic Minnaar, Application Engineer at Altair & Prof. Anton du Plessis from the CT Scanning Facility at the University of Stellenbosch, will present a case study to explain how Altair Inspire Cast and CT scanning enables the design of efficient casting processes.
This South African case study will demonstrate the collaborative value of Inspire Cast and CT scanning for profitable casting.
From Die Design to Defect-Free Castings: Shiva Tool Tech Achieves 80% Time Reduction with Altair Inspire Cast
Shiva Tool Tech is an automotive manufacturing focused, industrial powerhouse based in Pune, India. With over 25 years of experience in designing and manufacturing of gravity die casting (GDC), low-pressure die casting (LPDC), high-pressure die casting (HPDC) Dies, the company supports customers from manufacturing process design to the production stage. Manufacturing processes include milling, drilling, hardening, grinding, Computer Numerical Control (CNC) machining, Electrical Discharge Machining (EDM), inspection and polishing to get the final assembly of the casting die.
Inspire Cast 2019 Introduction
In this course, you will have the opportunity to learn about the Inspire Cast 2019 interface along with tools and workflows contained within Inspire Cast. Modules contained within the course provide detailed descriptions of the tools and workflows within Inspire Cast. You will also have the opportunity to watch and perform hands-on exercises within each module.
Inspire Cast - Getting Started
A course to help users get started using Inspire Cast including an interface tour and workflow training/videos.
Getting Started, Training Materials
How to Design Die-Casting Parts with Altair Inspire Cast
Presentation by El Abidi Ahmed, CAE Manager - Senior Expert at U-Shin Group.
ATC Presentations, Videos
Altair Inspire Cast High Pressure Die Casting Component Model
Downloadable high pressure die casting component demo model for Altair Inspire Cast.
Demo Models, Training Materials
Altair Inspire Cast Low Pressure Die Casting Component Model
Downloadable low pressure die casting component model for Altair Inspire Cast.
Demo Models, Training Materials
Altair Inspire Cast Tilt Pouring Demo Model
Demo model for tilt pouring for Altair Inspire Cast.
Demo Models, Training Materials
Introducing the Next Generation Manufacturing Simulation Solutions on Altair Inspire™ Platform
Altair manufacturing simulation tools have received an extensive amount of development efforts to expand their simulation capabilities.
Altair Inspire Cast Datasheet
Altair Inspire Cast was developed with its end users in mind. We strive to make casting simulation as easy as possible by using ‘foundryman’s language’ in our software. Every word in the interface comes from the casting process world. Not only is the software incredibly easy to use, it is also highly accurate and powerful. Get started with Inspire Cast today to further investigate and explore your casting process with just a few clicks.
The Complete Design for Additive Manufacturing and 3D Printing Toolchain
To successfully take advantage of the benefits of 3D printing and additive manufacturing, a new design and simulation process must be used. It is not beneficial to simply ‘print’ a current design. New tools and advanced computational power have enabled users to optimize solid geometries for stiffness and weight, and also allowed them to simulate loading conditions and lightweight designs. These new computational tools also give users the opportunity to test how a design will perform under real-world conditions.
Wisconsin Precision Casting Corporation
Wisconsin Precision Casting Corporation, an investment casting manufacturer utilized Altair Inspire and Altair Inspire Cast. for a design study that focused on the redesign of a regenerative turbine pump cover.
Altair Inspire Cast Gravity Casting Model
Downloadable gravity casting model for Altair Inspire Cast.
Demo Models, Training Materials
U-Shin is currently employing Altair Inspire Cast to perform testing and optimization to create sound, redesigned automotive parts.U-Shin has seen significant time and cost savings by utilizing Altair Inspire Cast.
Woodland/Alloy Casting Inc.
Woodland/Alloy Casting is simulating and testing aluminum casting projects in Altair Inspire Cast. By running simulations in Altair Inspire Cast, Woodland/Alloy Casting can more accurately predict defect-free castings, while reducing time and cost in the overall casting process.
Altair Offers Flexibility and Enhancement for Casting Process Design and Optimization
The goal of the project outlined in this paper is to get the optimal gating system (size and position of ingate) to help avoid porosity and other common defects in the produced parts, achieving the final design to begin casting the component.
Brochures, Customer Stories
3D Printing for Innovative Mold Making Combined with Simulation Driven Design Inspiration Push the Limits for High Performance Castings
Bringing design optimization, fatigue analysis, casting, and 3D printing together addresses the challenges of lightweight design and enables the creation of an innovative design and manufacturing process that enhances performance and efficiency.
Start-up Success with Simulation
Startup company amprove employs a series of cutting-edge simulation techniques to develop high-performance parts tailored towards a variety of manufacturing methods including, but not limited to, additive manufacturing and casting. As a result, amprove generates optimized parts, which enable them to meet the performance and economic needs of customers. In order to reach their goals, amprove needed an optimization solver they could rely on to provide accurate results. Having used Altair OptiStruct™ previously, they decided to reach out to Altair to pursue a potential partnership. During this process, the Altair team was pivotal in helping them join the Altair start-up program. Through the use of manufacturing simulation software such as Altair Inspire Cast and Altair Inspire Print 3D, amprove has been able to provide more polished solutions for their customers. Utilizing OptiStruct provided the opportunity to attain ideal designs with significant weight reductions, leading to a lower cost for amprove’s customers.