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    GIFA 2003 - Triumph Bonveillie Motorcycle DTD 05th May 2003

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    Pham Phuc
    Triumph UK began outsourcing casting production to manufacturers in Asia in the 1980s. One of their primary concerns was whether the local manufacturers could meet their critical surface finish requirements. Magma GmbH's casting simulation services helped optimize three aluminum casting components produced by a captive die caster in Malaysia for Triumph. The flow and solidification simulations identified critically filled sections and helped detect failure formations to provide a basis for die optimization improvements.

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    GIFA 2003 - Triumph Bonveillie Motorcycle DTD 05th May 2003

    Uploaded by

    Pham Phuc
    47 views42 pages
    Triumph UK began outsourcing casting production to manufacturers in Asia in the 1980s. One of their primary concerns was whether the local manufacturers could meet their critical surface finish requirements. Magma GmbH's casting simulation services helped optimize three aluminum casting components produced by a captive die caster in Malaysia for Triumph. The flow and solidification simulations identified critically filled sections and helped detect failure formations to provide a basis for die optimization improvements.

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    GIFA 2003- Triumph Bonveillie Motorcycle Dtd 05th May 2003

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    Triumph UK began outsourcing casting production to manufacturers in Asia in the 1980s. One of their primary concerns was whether the local manufacturers could meet their critical surface finish requirements. Magma GmbH's casting simulation services helped optimize three aluminum casting components produced by a captive die caster in Malaysia for Triumph. The flow and solidification simulations identified critically filled sections and helped detect failure formations to provide a basis for die optimization improvements.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    47 views42 pages

    GIFA 2003 - Triumph Bonveillie Motorcycle DTD 05th May 2003

    Uploaded by

    Pham Phuc
    Triumph UK began outsourcing casting production to manufacturers in Asia in the 1980s. One of their primary concerns was whether the local manufacturers could meet their critical surface finish requirements. Magma GmbH's casting simulation services helped optimize three aluminum casting components produced by a captive die caster in Malaysia for Triumph. The flow and solidification simulations identified critically filled sections and helped detect failure formations to provide a basis for die optimization improvements.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    of 42

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    Committed to Casting Excellence

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    Committed to Casting Excellence

    Background
    Triumph UK began started outsourcing since 1980s.

    One of their primary concern would the local


    manufacturers out in Asia will be able to meet their
    critical surface requirement which we can see evident
    in all of their bikes.

    Triumph UK have been making use of MAGMA Gmbh

    project services for many years now, and confident


    that these services is also readily available in MAGMA
    Asia Pacific, who is responsible for the development of
    3 casting components with local captive die caster in
    West Malaysia.

    The flow and solidification simulation should help to

    detect the failure formation and to provide a basis for


    optimization measurements
    Committed to Casting Excellence

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    Complete shot and final version


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    Committed to Casting Excellence

    Cam Cover - Aluminium

    Casting Geometry and Cooling System


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    Committed to Casting Excellence

    Process Route, Simulation Setup


    Alloy:

    ADC 12 (AlSi10Mg)
    Die material: SKD 61(~X20Cr13)
    Initial temperatures:
    Die:
    Melt:
    coolant (oil):
    spray (water):

    220 C
    680 C
    180 C
    20 C

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    Casting /Process Parameters

    Casting weight:
    1028 g.
    Shot weight:
    2017 g
    Plunger Diameter:
    90 mm
    Filling time:
    30 ms
    Gate velocity:
    31 m/s
    Flow rate:
    12723 cm3/s
    Filling pressure:
    135 bar
    Intensification:
    550 tons
    Machine :
    Buhler H-400B
    1st Phase Speed:
    0.25 m/sec
    2nd Phase Speed:
    2.00 m/sec
    2nd Phase Switch: 295.00 mm
    Committed to Casting Excellence

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    Cam Cover - Aluminium


    Time to fill a certain region

    Last sections
    to be filled

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    Committed to Casting Excellence

    Fill time plot, critical area


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    Committed to Casting Excellence

    Cam Cover - Casting

    Simulation vs Reality Check


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    Shifted the position of


    Spot cooling up problem
    resolve

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    Summary
    The flow analysis did found the casting

    sections that are critical for cold shuts


    and air entrapments due to insufficient
    venting.
    The flow analysis provides the
    information about the flow pattern of
    the melt
    This is the basis for die optimization
    measurements such as repositioning of
    the overflows and modification of the
    spot cooling lines.
    Committed to Casting Excellence

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    Committed to Casting Excellence

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    Committed to Casting Excellence

    Background
    One of the primary quality requirements

    of this component is the surface quality


    finish as the casting will undergo
    secondary plating flow mark, cold shuts
    cannot be tolerated.
    Magma tracer and filltime filling criterion
    is use extensively to analyze the flow and
    make changes to gating system to
    improve flow characteristics.
    The flow and solidification simulation
    should help to detect the failure formation
    and to provide a basis for optimization
    measurements
    Committed to Casting Excellence

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    Casting Final Version


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    Committed to Casting Excellence

    Aluminum Clutch Cover


    Casting Geometry and Cooling System
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    Committed to Casting Excellence

    Process Route, Simulation Setup


    Alloy:

    ADC 12 (AlSi10Mg)
    Die material: SKD 61(~X20Cr13)
    Initial temperatures:
    Die:
    Melt:
    spray (water):

    200 C
    680 C
    28 C

    Committed to Casting Excellence

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    Casting /Process Parameters


    Casting weight:

    2177 g.
    Shot weight:
    4270 g
    Plunger Diameter:
    120 mm
    Filling time:
    25 ms
    Gate velocity:
    54.5 m/s
    Flow rate:
    39584 cm3/s
    Filling pressure:
    135 bar
    Intensification:
    700 tons
    Machine :
    Buhler SC_D140
    1st phase Speed:
    0.25 m/sec
    2nd phase Speed:
    3.50 m/sec
    2nd Phase Switch: 700.00 mm
    Committed to Casting Excellence

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    Committed to Casting Excellence

    Aluminum Clutch Cover


    Time to fill a certain region

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    Committed to Casting Excellence

    Filltime Checking surface flow lines/flow marks

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    Committed to Casting Excellence

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    Committed to Casting Excellence

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    Summary
    The flow marks was successfully

    rectified through the modification of


    ingate thickness to control flow rate
    through each gate/
    The flow analysis help us detect flow
    lamination effect, that assist us to
    resolve secondary peeling effect after
    shot blasting.
    This is the basis for die optimization
    measurements such as repositioning of
    cooling lines.

    Committed to Casting Excellence

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    Committed to Casting Excellence

    Background
    One of the primary quality requirements

    of this component is the surface quality


    finish as the casting will undergo
    secondary plating flow mark, cold shuts
    cannot be tolerated.
    Magma tracer and filltime filling criterion
    is use extensively to analyze the flow and
    make changes to gating system to
    improve flow characteristics.
    The flow and solidification simulation
    should help to detect the failure formation
    and to provide a basis for optimization
    measurements
    Committed to Casting Excellence

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    Finish Casting Picture


    Committed to Casting Excellence

    Aluminum RH Cover Geometry Layout


    with
    cooling channels

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    Committed to Casting Excellence

    Process Route, Simulation Setup


    Alloy:

    ADC 12 (AlSi10Mg)
    Die material: SKD 61(~X20Cr13)
    Initial temperatures:
    Die:
    Melt:
    spray (water):

    220 C
    675 C
    28 C

    Committed to Casting Excellence

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    Casting /Process Parameters


    Casting weight:

    996 g.
    Shot weight:
    2178 g
    Plunger Diameter:
    90 mm
    Filling time:
    27 ms
    Gate velocity:
    32.8m/s
    Flow rate:
    15904 cm3/s
    Filling pressure:
    135 bar
    Intensification:
    700 tons
    Machine :
    Toshiba DC350CL
    1st phase Speed:
    0.25 m/sec
    2nd phase Speed:
    2.25 m/sec
    2nd Phase Switch: 340.00mm
    Committed to Casting Excellence

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    Committed to Casting Excellence

    Filltime Result Time to fill the cavity


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    Committed to Casting Excellence

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    Committed to Casting Excellence

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    Late solidification
    Around bearing hsg
    Possible
    Shrinkage
    Committed to Casting Excellence

    Summary
    The flow analysis did found the casting

    sections that are critical for cold shuts


    and air entrapments due to insufficient
    venting.
    The flow analysis provides the
    information about the flow pattern of
    the melt
    This is the basis for die optimization
    measurements such as repositioning of
    the overflows and modification of the
    gating system
    Committed to Casting Excellence

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    Thank very much for listening


    Committed to Casting Excellence

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