Producing Dependable Metal-Casting Quality through Process Simulation 

Very often people producing ferrous and non ferrous castings struggle by hit and trial methods to come up with components which are expected to meet MIL SPECS or AERONAUTICAL STANDARDS. 

A lot of times, the process is held hostage to the experience of experienced persons. Precious time, resources and morale is lost during this kind of experimentation. 

"Metal Casting (Ferrous & Non-Ferrous) in Pakistan is mostly done by Hit & Trial methods. In order to reach MIL-SPECS or AERONAUTICAL STANDARDS, foundries go through a chain of failed attempts and become hostage to the "experience" of "the experienced person" present in their organizations. 

Leaving aside the orthodox methods of casting, there are other variables in the Casting Process which can be modified easily to reach the desired standard. For this, experiments are done again and again which result in Loss of Valuable resources like time, material and add to frustration. 

This lead to many compromises on the quality during the process and the

end result is expensive production, numerous rejections and loss of time.

With the help of Computer Aided Software, we can simulate the complete

casting Process and can control almost all variables on which the quality of casting depends. This can help Foundries to carry out all Hit & Trials on the Computer and optimize the process beforehand. 

Simulation software helps the experts in carrying out a number of quality related analysis on the process. To mention few:

  Ø  Filling Pattern

Ø  Cooling Variation Pattern

Ø  Solidification Pattern

Ø  Shrinkage Analysis

Ø  Porosity Analysis

Ø  Air Voids/Gaps

Ø  Gating/Riser System Modification

Ø  Stress Analysis during Cooling

Ø  Grain Structure Analysis

Ø  And Many More

Learning objectives:  

1.    Computer Aided Engineering ( Simulation)

·         General Overview (Different Types of Manufacturing Process Simulations) 

a.    Stress

b.    Fatigue

c.    Flow

d.    Vibration Acoustics

e.    Casting

f.     Forging

g.    Sheet Metal Forming

h.    Rolling 

2.    Main Focus 

·         Casting / Foundry Process Simulation 

a.    Sand Casting

b.    HPDC

c.    LPDC

d.    Gravity Die Casting 

·         Forging/Forming 

a.    Hammer

b.    Press 

Potential Participants  

1.    Defense Related Manufacturing[Foundry, Forging & Fabrication]

2.    Senior Executives/Heads of Manufacturing Industry

3.    Design / R & D Engineers & Concerned Decision Makers

4.    Manufacturing Engineers 

Profile of Trainer 

Major ® M. Arfaeen Iqbal CEO, Marriala Consultants is a UET graduate in Electronics and has more than 19 years of experience in Defense Manufacturing and Private sector. He is Technical Consultant to number of Manufacturing/Fabrication Companies for modernizing their manufacturing processes through CAE techniques. He works in collaboration with international CAD/CAM/CAE solution providers.  

Mr Zeeshan Anwar from Marriala Consultants is a graduate in Mechanical Engineering from UET, Lahore and has professional experience in teaching CAD/CAM methodologies and has imparted state of the art CAD/CAM training to leading educational and industrial sector of Pakistan.

Duration        =          08 Hours