In order to produce castings with optimized quality while minimizing production costs, Shakespeare engineers have mastered their casting processes without creating numerous sample castings.
Casting process simulation is one tool that Shakespeare employ to accurately predict mould flow rates, cooling effects and porosity analysis of their cast product. In this way, casting process simulation minimizes production risks and helps realize the potential of all types of materials in economical and robust manufacturing processes.
At Shakespeare we analyse mould pouring and flow rates to optimise the design of the pattern, in particular ensuring we have a robust layout of ingates, runner dimensions, venting, feeders and chills.
The gate and riser system design is essential to ensure that the molten metal can get into the pattern before it starts to solidify, thicken and essentially stop running into some of the far reaching areas of the casting. We also can predict mould erosion and sand burn-on/penetration, as well as track sand inclusions.
Only by the process of design reiteration and refinement, using computational fluid dynamic software, can our engineers be satisfied that the selected gate and riser system will eliminate undesirable effects in the final cast product, from poor flow.