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Challenges • Problem Castings

Sarginsons solve casting problems

The inability to make accurate prototypes often leads to difficulties at the production stage which are tolerated, at a cost, rather than remedied. Sarginsons is perfectly placed to remedy these issues by using digital twin simulations to determine the true nature of the problems. and generate a solution, before production commences. All without having to experiment with tool modifications, stopping production, or the uncertainty that this entails.

Sarginsons has undertaken everything from complete component redesigns to relatively minor tweaks and tool modifications, but all have one thing in common, a huge saving from better quality castings. And it's not just the casting process; problems are also found in heat treatment, CNC machining and surface finish, solutions to which Sarginsons has spent many years addressing. 

All problems can be remedied, some more quickly than others, but it is always better to virtually test before production.

Casting Is All Variables

Castings are susceptible to an enormous number of variables which means any change to the process, however slight, can cause the casting to deviate from the required geometry and mechanical properties. And moving from casting prototypes, in sand, to full scale production is riven with potential variabilities, particularly with larger or more complex castings. 

Virtual Testing Is Vital

The ability to accurately simulate the TYE and fatigue of a casting is a good starting point for remediation, but augmented solidification studies, heat treatment simulations and mechanically accurate sand castings are also a vital part in determining the correct solution. Where component design is thought to be problematic Sarginsons unique DfM+ is also invaluable.

The Industrialisation Hub

Sarginsons Industrialisation Hub is designed to predominately act as a precursor to principal production. The idea is that testing and ramp up volumes can be used as test beds to accommodate variabilities, before they appear in full production. Whilst this approach can be used to avoid production issues it is also capable of quickly resolving issues that have already arisen.

Key Points

  • Simulations Simplify Problem Resolution
  • Tooling Technologies Have Advanced
  • Rapid Iterative Design Refines Options
  • Huge Cost and Quality Economies
  • No Need To Stop Production

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Problems Don't Exist, Fear Does

With precise twin simulations, allowing numerous design iterations to be validated, Sarginsons can quickly find solutions to any casting problem and use it's production technology to find, without risk, the perfect solution.

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