Method Engineering & Process Modelling

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Audra Cobb
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1 Technical Workshop for Foundry Engineers Method Engineering & Process Modelling May 12 & 13, 2015 The University of Sheffield AMRC Knowledge Transfer Centre Sheffield Rotherham, UK Hosted by Castings Technology International

2 In a foundry environment, the application of effective Method Engineering requires a thorough understanding of mould gating, running & feeding principles, careful selection of casting parameters and an in-depth appreciation of fluid dynamics, heat transfer and alloy solidification. For many foundries this knowledge is held only by experienced engineers. In recent years, the design of gating systems has been assisted by the development of computer aided process simulation. These process models, substantiated by an adequate database, are now sufficiently mature to enable skilled foundry engineers to design effective gating systems and to simulate mould fill and solidification in the virtual world, whilst minimising the number of trial iterations required in the real world. In addition predictive process modelling can assist in predicting grain size, residual stresses and partdeformation providing a significant amount of information in order to define a sound product engineering definition. The two-day workshop will be held at the location of University of Sheffield AMRC, in Rotherham. The programme includes a one-day seminar at the Knowledge Transfer Centre building with a variety of presentations and case studies focusing on the important discipline of Method Engineering and the supporting role of Process Modelling, followed by a half-day visit to the facilities of Cti (a subsidiary of the University of Sheffield and a leading provider of technology, expertise and services to the cast metals sector). It is not always possible to have access to these sophisticated models or to have the necessary material data to have accurate simulations. The workshop aim is to illustrate in a practical manner, direction to this approach: the importance of Method Engineering and the excellent support provided by the Process Modeling tools, to this end this workshop will cover demonstrations of computerised simulation systems together with the practical empirical approach to designing effective gating systems. The seminars will provide a unique opportunity for foundry practitioners and engineers to hear, first-hand, the important principles of good Method Engineering. The seminar sessions will be followed on May 13th, by a tour of Castings Technology International research facilities to complement in a practical manner the concepts and experiences acquired the day before. This knowledge of Cti will allow seminar attendees to understand the research and development services that Cti can provide to the Investment Casting community and how to gain access to leading edge technology Venue : Knowledge Transfer Centre at the University of Sheffield AMRC Rotherham Transfers by Bus to Venue from Hotel are available to delegates (organized by EICF) Workshop Hotel : Hampton by Hilton Sheffield Book room using negotiated rates, per room per night, available up to April 13th /index.jhtml?WT.mc_id=POG

3 Workshop Programme Tuesday May 12 08:30 Registration 09:00 Workshop Welcome by EICF President Michael Ruenz EICF President 09:05 Insight into the Power of Process Modelling Badarinath Kalkunte (Product Marketing Manager - Casting Solutions ESI Group) 09:45 Validation and Application of Process Modelling of Aerospace Investment Castings Paul Tennant Technical Specialist - Process Modelling. Rolls-Royce plc 10:15 Coffee Break 10:45 Process Modelling of Replicast James Collins Foundry Process Consultant - Castings Technology International 11:15 A Practical Approach to Method Engineering Steve Leyland Technical Director - Uni-Pol Group 11:45 Investment Casting Mould Optimisation by means of Advanced Simulation and Instrumented Fibre-wrapped Moulds Dr Antton Melendez Foundry and Steelmaking Projects Manager - TECNALIA 12:15 Pushing the Limits of Investment Casting: Large Casting Housing Case Studies Manuel Caballero Technical Director - Ecrimesa 12:45 LUNCH

4 Afternoon Session 13:45 Improving Mould Fill Simulation Capability and its Role in Inclusion Reduction Xabier Esquisabel / Ignacio Dominguez Process Design and Modelling Leader / Engineering Director - PCB 14:15 Numerical Prediction of Misruns and Porosity for Investment Casting Applications Dr. Julio Aguilar Head of Casting Processes and Techcenter- Access 14:45 Improving the Accuracy of Investment Casting Mould Filling Simulations Vanessa Indrizzi PhD Student - University of Birmingham 15:15 Coffee Break 15:45 Prediction of Typical Casting Defects via Numerical Modelling Andrea Carosi Airfoil Technical Manager - Precicast 16:15 3D Metrology of Turbine Aerofoils through the Various Stages of the Casting Process Stephanie Adolf Sales Operations Manager - GOM mbh - Industrial 3D Measurement Techniques 16:45 Future Simulation Trends in the Industry Marco Aloe COO - ESI UK, Scandinavia, India, Middle East & Africa ESI Group 17:15 Workshop closure Steve Irwin EICF Vice President 19:00 Workshop Dinner Kelham Island Museum - Sheffield

Wednesday May 13 Visit to Castings Technology International 09:00 Depart to Cti University of Sheffield AMRC 9.30 Arrival 9.45 Introduction to Cti 10.00 Tour (1.5 hrs) 11.30 Cti presentation 12.

5 Wednesday May 13 Visit to Castings Technology International 09:00 Depart to Cti University of Sheffield AMRC 9.30 Arrival 9.45 Introduction to Cti Tour (1.5 hrs) Cti presentation Light lunch Departure **Visitors to Cti should comply with security requirements as defined by Cti Visitors Policy ** All non-uk nationals must provide Cti with a copy of the photo page of their valid passport, showing their nationality, passport number and date of birth. Unfortunately, Identity Cards are not an acceptable alternative. This information must be sent to Cti (eicf2015@castingstechnology.com) at least 2 weeks prior to the Workshop. Further details from the EICF office secretary Julie Boyce julieboyce@eicf.org Registration forms can also be downloaded from

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