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Software Solutions for the Indian Die Casting Industry

| Author/ Editor: Ahlam Rais / Isabell Page

In order to be able to supply high-quality products, software must be constantly updated. Due to this three latest software releases are discussed in order to support the indian die casting market.

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To stay ahead in the industry, manufacturers have to offer superior quality products that adhere to international standards as well. Making use of the latest software is one of the core steps in this direction.
To stay ahead in the industry, manufacturers have to offer superior quality products that adhere to international standards as well. Making use of the latest software is one of the core steps in this direction.
( Source: Pixabay / CC0 )

Die casting is a highly specialized sector which requires constant upgrades especially in terms of software in order to deliver superior quality products. In this context, three of the latest software releases: Inspire Cast by Altair Engineering, PowerMill 2019 by Autodesk and Mastercam Mill 2019 have been discussed in detail for the benefit of the Indian die casting market.

The dies and molds market in India is expected to grow at a CAGR of close to 9% from 2018–2022, states a report by market research analyst, Technavio. The forecasted growth can be attributed to the popular "Make in India" slogan of the Indian Government. This scenario showcases the opportunity that exists in the Indian market for manufacturers in the die casting industry.

To stay ahead in the industry, manufacturers have to offer superior quality products that adhere to international standards as well. Making use of the latest software is one of the core steps in this direction. What are the latest software upgrades available to manufacturers in the Indian market?

Inspire Cast by Altair Engineering

The Inspire Cast software by Altair Engineering is capable of developing superior quality products and even enhancing designs to create better components. The easy to use and accurate software enables manufacturers to simulate gravity die, gravity sand, investment, high pressure, low pressure die casting and tilt pouring with ease. Five new features have now been incorporated in the software such as New Components, Cooling Lines, Pipe Shrinkage, Exothermal Support and Microporosity.

  • New Components:

This stunning feature assists one to design or generate additional casting components. It is equipped to identify or generate components such as core, chiller, riser, and more. The materials for these components can also be selected and components can be resized using the geometry tool.

  • Cooling Lines:

It is often witnessed that during the casting process, parts tend to get hot spots of porosity in inconvenient places. Now, the cooling lines feature can help reduce those defects and promote even solidification rates. The "generation tool" and "creation/manipulation" options also enable one to easily create and position cooling lines. Optimized designs are also achieved, thus allowing manufacturers to make informed decisions and also save time as well as money.

  • Pipe Shrinkage:

Inspire Cast allows one to detect casting defects easily. The simulation is divided into two stages, filling and solidification. The result type of temperature, solid fraction and the visualization of shrinkage porosities will allow a person to detect both the location and the size of the risers. Macroporosities are shown for an enclosed void of low density due to thermal shrinkage. Pipe shrinkage enables users to detect and dimension isothermal and exothermal sleeves.

  • Exothermal Support:

This feature proves beneficial for the casting solidification procedure. In a situation where metals need to be in a liquid state for a longer period of time, this feature acts as a savior in which better feeding efficiency is achieved.

  • Microporosity:

Microporosity is a minuscule defect that occurs in cast parts yet has devastating consequences on the quality of the project. It's associated with the Niyama criteria which can be defined as the relationship between high cooling rate and temperature gradient and differs from material to material. The Microporosity feature plays a vital role here.

Autodesk’s PowerMill 2019

Autodesk’s PowerMillis an interesting CAM innovation which is one of the most comprehensive milling solutions for high-speed and 5-axis machining. The software is used to manufacture molds, dies, and highly complex parts. The PowerMill 2019 offers new abilities for additive manufacturing, with improved high-efficiency roughing, simpler 5-axis collision avoidance, enhanced collaboration and CNC machining setups. Recently, the software has also received an upgrade – the PowerMill 2019.1. The newly revamped software comprises diverse features but the core ones include posts in the cloud, surface probing and interactive collision avoidance. Other features comprise setup improvements, an enhanced automatic tool tilting, Vortex from stock stepover, and a pattern turning.

  • Posts in the cloud:

This new feature offers manufacturers the flexibility to manage their post-processor files more effectively. Now, all post-processor files can be stored at a secure cloud-site and manufacturers are left assured that all the teams are working with the most updated file. This leaves little room for doubt and confusion. This simple step avoids one to depend on emails which are capable of making version control challenging.

  • Interactive collision avoidance:

Autodesk offers a collection of additional interactive collision management tools which makes it easier for programmers to identify and avoid collisions or near-misses involving the cutting tool assembly and workpiece.

  • Surface probing:

The software now includes 3D surface probing to help manufacturers understand how accurately parts are machined. Spindle-mounted probes are used to measure parts during the manufacturing process. Users can also share 3D inspection reports via Autodesk Drive – a cloud-based collaboration tool – to allow production quality issues to be addressed quickly and efficiently.

Mastercam Mill 2019

Mastercam, the US-based firm has introduced Mastercam Mill2019 for its Indian customers. The software is easy to learn and use. In addition, thelocal teams provide exceptional support and training. Mastercam Mill with the recent updates and new features improve productivity with strategies such as the OptiRough toolpath and a Toolpath Refinement Algorithm. OptiRough is a 3D full flute roughing toolpath based on Mastercam's Dynamic Milling technology which dramatically improves roughing throughput and reduces tool wear. Whereas, the Toolpath Refinement Algorithm produces ultrahigh finishes to slash polishing requirements.

Instead of using just the tip of the tool with high engagement and low speeds, the OptiRough approach turns conventional wisdom on its head, always using as much flute length as possible at high speeds with minimal engagement. OptiRough constantly monitors tool engagement and adjusts the toolpath to maintain a consistent load on the workpiece and the tool.

In a lean mould making shop that builds injection molds, vacuum form, and die cast tooling for customers in the consumer products, recreational vehicle, and medical device manufacturing industries,the OptiRough feature proves beneficial as it can reduce roughing time between 50 % and 75% on machining centres and tooling costs are lowered by about 25%. For the back end of the manufacturing process, Mastercam's Toolpath Refinement algorithm makes it possible to achieve exceptional high finishes that in the past were only possible after hours of manual polishing with a stone. Toolpath refinement provides the CNC machine's controller with an ideal point set for the optimal management of acceleration and deceleration in confined areas of the part to produce a more uniform and finer finish that was heretofore impossible to obtain without hand polishing.

These are just some of the latest software products that show their presence in the Indian market through their innovative solutions.

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