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CASTING INNOVATIONS


Casting Simulation Helps Part Conversion Woodland/Alloy Casting Inc.


(Racine, Wisconsin) is a full-ser- vice aluminum casting provider that serves industries such as aviation, electrical, industrial, marine and defense. Te company specializes in


green sand molding, air set mold- ing and permanent molding, and has the capabilities to cast parts that weigh a few ounces, all the way to 2,000 lbs. Te company was faced with a


challenge when it was transition- ing a marine exhaust housing part from a lost foam casting to a sand casting with an updated gat- ing system. Of course, they had to keep the part sound, functional and dependable. With this material modifica-


tion in mind, there were a num- ber of factors to consider when manufacturing this new casting.


“We wanted to produce a sound


casting, while still keeping ingates and risers to a minimum, this would allow for the yield to remain low and help reduce the time needed to remove the rigging,” said Andy Ceretto, quality control manager, Woodland/Alloy Casting. In order to create this sand


casting, a new gating system was designed that would feed the casting from the bottom flange and push the metal to the top of the cast- ing. Once the updated design was finalized, Woodland/Alloy Casting tested the new gating system by running a simulation in Click2Cast by solidTinking (Troy, Michigan). Woodland/Alloy Casting was


able to conclude the new gating system would produce a casting with zero defects. Before utilizing Click2Cast, Woodland/Alloy Cast- ing would have conducted numerous


costly and time-consuming tests, requiring a number of molds to determine the outcome of the new gating system. “By employing Click2Cast,


we were able to conclude the new gating system would work properly after running just two simulations,” Ceretto said. With the enhanced casting pro-


cess in place, Woodland/Alloy Cast- ing is continuing to see the benefits of both cost and time savings due to the simulation capabilities that are offered in Click2Cast. Woodland/Alloy Casting has


employed Click2Cast on a num- ber of casting projects since first discovering the software last year and is continuing to explore all the features, settings and tools that the software provides. For more information, visit


www.solidthinking.com/click2cast


42 | MODERN CASTING July 2017


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