CPT International 02/2017

SIMULATION
Lu Baosheng, Changchun, China
Manufacturability of a cylinder
block sand core
Quality sand cores are a natural requirement for most high integrity castings. Just as for the castings,
the challenges are related to technical, environmental and cost aspects. One key factor for a
robust core production is manufacturability: the reliability of production considering the given facility
conditions. For FAW Foundry, core process simulation using MAGMA C+M is an important
tool to establish a robust state-of-the art production of lightweight automotive cylinder blocks
Sand core production is as complex
and demanding as the manufacture of
metal castings. A robust and high quality
production means efficient development,
reduced energy consumption
and waste, and foremost a guaranteed
consistent quality. A typical example
for these diverse targets is a core for an
automotive cylinder block being produced
for a renowned and internationally
active automobile company.
Through the consequent and early use of MAGMA C+M The FAW engineers have
saved a considerable amount of resources (Graphics: MAGMA)
Simulation at the initial
design of cores
When engineering a new product, the
FAW team, Changchun, China, uses
simulation to develop and verify their
shooting and curing process as early as
possible to ensure an effective development
process. The complex interaction
of sand and gas flow during core box filling
and binder curing can be visualized
and assessed at early stages of the design
and without the need for real core boxes
and experiments. FAW operates several
types of core shooting machines,
with different types of shoot heads, core
boxes and cores. To effectively plan the
work flow in their facility, knowledge
regarding the machine configuration
and shooting and gassing parameters
suited to produce each core is essential.
The key point was: Could FAW
manu facture the cylinder block core
on different machines, possibly with
different core boxes and core designs?
When challenged with this question,
the FAW engineers had already
successfully developed Design
A, combining their experience with
26 Casting Plant & Technology 2 / 2017