R&D: Shape at ideas
It is important to start in a good way in order to minimize production wastes and follow corrections. To make this true, we do a preliminary evolution of the product and of the casting system. It is important to support the customer during the research and the development of new products in co-design, in order to obtain an efficient and functional product.
Customer’s distance isn’t a problem: we are your partner also on the other side of the world!
We give you our experience to put on the product all the possible changes and the necessary tricks to achieve the success, not only for the casting but also for the trimming, cleanliness and assembling. All these activities are made with the customer. We create, when possible, the three-dimensional model of the part directly in native format, for a complete compatibility and frankness with the customer.
This is an utmost importance phase and for this we dedicate it all our consideration.
Casting simulation it is a process integrated in the die design.
After the developing of the gate system, this is simulated with the help of the simulation software, through an iterative process which begin with approximate and quick simulations of the first draft and then it improves with the aim to reduce expected defects and production wastes.
The simulations are carry out even if you want to find and solve production problems by changing existing dies of other manufacturers or also as simple consultancy service to foundries. We use the FLOW-3D software, produced by the American Flow-Science (www.flow3d.com).
For the structural analysis of our molds we use ANSYS MECHANICAL, one of the best known finite element analysis (FEA) software for structural engineering. From the results of the casting simulation it is possible to import the pressure and temperature data during the different casting phases and to include them in the structural model of the mold.
Thanks to this tool it is possible to:
- View the true distribution of internal and external stresses in the molds and prevent fatigue failure.
- Evaluate the clearance between the components of the mold and the relative contact pressure and foresee the formation of any burrs.
- Analyze and predict cavity cracks caused by thermal stress fatigue.
- Predict stresses and deformations of cast components and make necessary corrections to nominal dimensions
- Optimize the shape of the mold and reduce the weight of the structure ensuring the required rigidity and thermomechanical resistance.
Application of new materials and treatments
FORM relies on the best steel’s suppliers, such as BÖHLER, AUBERT&DUVAL, UDDEHOLM and the most reliable tratmentists. The synergy between their knowledge and our experience allow us to combine the more suitable material with every kind of application. Our knowledge in this field derived from years of activity in close contact with customers, for those we do regularly maintenance and reinstatement of the die on production.