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Development of a new solidification simulator prototype for the modernization of the south african foundry industry

Development of solidification simulation software prototype for foundries. It will be used as researching and advising tool on foundry technology centers and it will be putting on the international market for its commercialization

Development of solidification simulation software prototype for foundries. It will be used as researching and advising tool on Foundry Technology Centers and it will be putting on the international market for its commercialization. - Technological development expected: .Net technology software with the following basic characteristics: o Importing IGS format files from casting models and obtaining structured meshes. o Heating and mass transfer simulation of the model using algorithms based on finite differences and finite elements. o Analysis of the feeding capacity of the different areas of the model using algorithms based on Operational Research based on Graph Theory. o 3D visualization interface of simulation results with color codes and correctness / incorrectness indicators of the model. - Product market, process or service objective of EUREKA Project Initially the product will go to the South African foundry industry and technology centers that advise the industry. However, the partnership agreement will be extended to the entire African continent and later to the international market of casting. The use of simulation tools generally has two clear advantages: 1. Anticipating the problems that may arise in manufacturing time and seek solutions to avoid them. 2. Optimize the resources needed for manufacturing. In the case of a casting simulator, these advantages result in: 1. Minimize the number of parts with solidification defects (shrinkage, micro shrinkage, porosity ...) 2. Use the smallest possible volume of feeders, which means reducing the total volume of metal molten thus saving energy and manufacturing costs. To design a casting model without prior simulation, the only way is to use trial and error testing, discarding the models that produce defects, changing at a guess the design and testing again until we get useful parts. In the final model is used to oversize feeders to take less risk. Although there are other simulations software, the development methodologies used by each of them are closed and may not give the expected results in all different qualities. The alliance between MCTS and AMV Soluciones will manage the increased activity of the different South African institutions of the foundry sector to create a living tool, with continuous improvement, thanks to the influence of the MCTS with African foundries and the proved knowledge of AMV Soluciones, not only in the field of simulation, but also in Operations Research. Description of the new product. The product will be a software for the simulation of casting metal models for all metallic qualities. Differential aspects. o Regarding African market, it will be the only software developed with the collaboration of a technology center of this continent (MCTS), which is an important advantage from the point of view of counseling and for the adaptation of the application to each foundry. o It will have competitive prices on this continent. o AMV Soluciones has already other software solutions exclusively developed for this sector, thus the application can be integrated in a suite simulator casting, more agile and with more possibilities for data connection and accumulation of know-how than using other non-integrated applications. o AMV Soluciones has developed IO libraries with Euclidean graphs of own definition that have already proved their efficiency when analyzing potential metal flow during the solidification process, that will bring new possibilities to study casting defects.
Acronym: 
S4FOUNDRIES
Project ID: 
9 186
Start date: 
01-01-2015
Project Duration: 
36months
Project costs: 
400 000.00€
Technological Area: 
Computer Software technology
Market Area: 
Steel / Metalwork

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