Based on the product model of our customers we generate a complete 3D database of the core package and a 3D database of the casting geometry. The database represents all casting specific production requirements like machining allowances, radii, draft and core printing. A systematic approach of core printing and core clearances guaranties precise and reliable core packages. Each 3D database is always perfectly coordinated for its own particular requirements, beginning with rapid prototyping and migrating to high volume production.
Set the direction for success
BECKER stands for high engineering efficiency which is achieved by effective program management, latest hardware and software, and seamless data transfer because we use the software of our customers.
Whether the casting geometry, core package geometry, or tooling geometry – the 3D database always plays the key role in the planning for your success.
3D database including validation
We generate the tooling geometry based on the core package geometry. The tooling geometry completely describes the finished tooling including partings and slides. Design errors that are detected during machining or on a dynamometer can create large financial penalties and time delays.
Therefore, our responsibility for quality and economic efficiencies requires a detailed validation of each 3D database. Due to the detailed definition of our 3D database we validate wall thickness, machining allowances, assembly clearances before the tooling is manufactured or parts are cast.
The 3D tooling design is generated in close coordination with the foundry and the tooling manufacturer.
Advanced parametric designs allow for effective and flexible program execution. The 3D database is used to generate detailed tooling drawings. Each design is specifically customized to rapid prototyping, low volume production, or high volume production.
Complex processes and test procedures are simulated to avoid errors resulting in both cost and time savings for our customers and us.
Therefore, we take advantage of the following computer simulations:
- Moldfill and solidification simulation
- Computation of residual stress and distortion.
- Computation of mechanical properties including dendrite arm spacing (DAS).
This allows us to make the appropriate changes prior to tooling manufacturing or casting of the first part.
The target: Quality will be maximized while risk, cost, and timing will be minimized.