MAGMASOFT V5 Flow Simulation program is used in order to make the verification of the design of the runners at the molds. Simulation studies are repeated until the Best and Robost result is obtained. During this process, the following casting parameters are checked: Ingate vel

Ingate velocity

Cavity filling time

Temperature

Air entrapment

Flow direction

Hot spots

Solidification

Potential shrinkage and gas porosities

At KDS Casting, Mold and Process design studies are simultaneously carried out. With this principle throughout the following stages the process design and mold design is completed collectively and in the advanced product quality planning and product approval processes are applied in comformance with ISO/TS 16949 and German VDA Standards.

Improvement Suggestions for Mold and Process designs are also been made on each Project to the Customers.

STAGE 1 - RECEIVING 2D AND 3D DATA OF THE PRODUCT FROM THE CUSTOMER AND PERFORMING MOLD & PROCESS OPTIMIZATION STUDIES

STAGE 2 - DETERMINATION OF THE NUMBER OF MOLD EYES AND THE TONNAGE OF THE MACHINE TO BE USED, WHICH ARE THE MAIN DESIGN ELEMENTS

STAGE 3 - DETERMINATION OF MOLD PARTING LINE, MOLD RUNNER POSITIONS, AIR POCKET POSITIONS, PUSHERS, EXIT ANGLES, WALL THICKNESSES AND CORE DESIGNS

STAGE 4 - SIMULATION AND SOLIDIFICATION ANALYSIS STUDIES ARE CARRIED OUT. IMPROVEMENT OF THE MOLD DESIGN TO AVOID POROSITY AND SHRINKAGE ERRORS