Computer-aided engineering (CAE) is an important part of precision casting. It is an advanced technology that helps generate, analyze, and optimize the mechanical properties of a casting before its actual production. The use of CAE in precision casting helps to reduce the trial-and-error required for the production process, thus reducing cost, cycle time and improving quality.
CAE can be divided into two parts, explicit and implicit. Explicit CAE involves explicit geometrical representations and requires much more computational power than implicit CAE. In precision casting, explicit CAE is used to simulate the process of casting and explore the mechanical properties of various materials. Implicit CAE involves implicit or approximate geometrical representations and is used to analyze small components such as those used in automotive and aerospace industries.
Implicit CAE is generally easier to use because it requires less time to set up compared to explicit modelling. Therefore, it is a popular method in the analysis of complex parts and components. It is used to design and analyze internal features such as cooling channels, cooling systems, gate and runner designs, cooling times, and gating-and-riser system effects. Such design helps to ensure more consistent part quality and reduce the cost associated with casting defects.
Explicit CAE is often used to analyze large components that are more difficult to analyze using the implicit CAE method. This type of CAE can predict the thermal profile, as well as the casting defects that might occur during the process, which helps ensure that the parts produced will meet the required design specifications.
CAE is also used for the production and optimization of core-and-mold systems. In this process, the core and mold are designed using CAD software, and then CAE software is used to simulate the casting process and analyze the core-and-mold performance. This helps to reduce the design time drastically, and ensures that the components produced will have the required features and meet the desired specification.
With the increasing use of CAE, precision casting has become much more efficient and reliable. Furthermore, it has allowed manufacturers to produce complex parts at a fraction of the time and cost of traditional manufacturing techniques. This has opened up a wide range of new manufacturing possibilities and greatly increased the competitive advantage of the casting industry.
CAE is an incredibly powerful tool in the precision casting industry, and is an integral part of the modern production process. Its use has enabled the increased reliability, precision, and cost savings seen in todays castings, and will no doubt continue to do so in the future.
