ESI Group, a leading innovator in virtual prototyping software and services for manufacturing industries, announces the new version of its casting simulation software ESI ProCAST; a virtual manufacturing solution of ESI that enables foundries to improve the design and quality of the parts they produce. With ESI ProCAST, they’re able to predict manufacturing defects early and without the need for costly physical try-out. Consequently, they can correct part design and manufacturing processes well-ahead of production, achieving lower scrap rates and delivering quality parts in a consistent way. ProCAST 2016 promises even quicker turnaround times with new workflows dedicated to Gravity Casting and High Pressure Die Casting. Set-up time for gravity casting the most widespread sand casting process is reduced to just a few minutes, while the workflow for high pressure die casting addressed machine selection and bridges the gap between design and production to deliver increased efficiency on the shop floor.
Casting simulation helps industrial manufacturers and foundries comply with new and increasingly stringent market expectations and achieve the highest quality and productivity possible. To that end, ESI ProCAST provides a complete solution, covering all casting processes and the alloys used in diverse industry sectors and the latest 2016 version focuses on key industrial challenges specifically related to sand, investment and die casting processes in the automotive, aerospace and heavy industries.
In regard to sand casting processes, ESI ProCAST 2016 has been enriched with a dedicated workflow for gravity casting; enabling simulation set-up within minutes. Taking all process parameters into account to deliver highly precise results, this step-by-step approach can be customized to fit any foundry’s specific requirements and processes, delivering improved usability when repeating tasks. The new functionality is easy to use and can be mastered by any foundry man within a few days.
Another notable enhancement to ESI ProCAST 2016 is the introduction of the machine selection workflow that draws on a dedicated database for high pressure die casting (HPDC) machines, including the Colosio machines. The new functionality enables the user to define the operating point and operating zone for any machine, using the Pressure (P)-Flow Rate(Q)² graph. This information is linked to ProCAST’s solver to achieve virtual piston control in real time. Enabling a user to set-up parameters just as on the real machine, this enhancement provides a considerable time gain for process-design, and delivers the possibility to run a virtual benchmark and select the appropriate machine for specific jobs.
Finally, a die casting machine and a simulation software are able to communicate properly to facilitate the lives of foundries. Transforming reality into virtual and vice versa is no longer just a project, but a reality for all our customers, says Davide Colosio, CEO of Colosio S.r.l.
For more information about ESI ProCAST, please visit www.esi-group.com/casting or contact your nearest ESI office.
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