HOT CHAMBER & COLD CHAMBER
THE
KEY
OF
MIND
HOT CHAMBER & COLD CHAMBER
THE
KEY
OF
MIND
Simple and intuitive data entry of the casting geometry properties, by mean of weights and dimensions, as measured on an actual casting or on the STL cad model, when available. Automatic thickness analysis of the cad model can be performed to identify the critical areas easily.
Import of the casting’s geometry via stereolithographic file (STL), the universal exchange format available in all commercial and free CADs. Automatic “one-click” geometry repair and optimization.
An expert system that translates practical foundry experience into algorithms. Advanced mathematical calculations are translated into terms typically used in foundry for an easy and direct understanding.
Results are calculated taking into account the casting alloy, the defined quality targets and the actual process parameters. The standard and huge database of HPDC presses, alloys and die-steels can be customized on specific requests.
Calculation of the optimal gating and air evacuation system cross-sections (vacuum valves or chill vents). Calculation of the optimal process parameters. Choice of the proper die-casting machine and optimal plunger diameter.
Evaluation of the critical issues and reliability of the process based on an expert system. Practical, interactive tips that help to optimize the mold and process. PQ2 press-mold diagram analysis.
CastleKEY is the simple and immediate solution for foundry technologists and mold makers
CastleKEY offers the well-known features of its big brother CastleMIND, but with a minimal and intuitive interface aimed at minimizing purchase and management costs as well as geometry preparation and software learning times. Importing geometries is very simple since CastleKEY offers simple “one-click” tools to heal the geometries and improve their resolution when necessary.
CastleKEY is the simple and immediate solution for foundry technologists and mold makers
CastleKEY offers the well-known features of its big brother CastleMIND, but with a minimal and intuitive interface aimed at minimizing purchase and management costs as well as geometry preparation and software learning times. Importing geometries is very simple since CastleKEY offers simple “one-click” tools to heal the geometries and improve their resolution when necessary.
Expert System
It is a simple tool for the mold designer and for the foundrymen, which provides, in real-time, extremely practical indications without the need to launch expensive and time-consuming filling simulations. It not only identifies problems but also suggests how to solve them. It does not provide a generic assessment of a standard situation but predicts the actual work scenario of the given mold on the given machine based on the foundry experience integrated into its calculation engine.
Expert System
It is a simple tool for the mold designer and for the foundrymen, which provides, in real-time, extremely practical indications without the need to launch expensive and time-consuming filling simulations. It not only identifies problems but also suggests how to solve them. It does not provide a generic assessment of a standard situation but predicts the actual work scenario of the given mold on the given machine based on the foundry experience integrated into its calculation engine.
Cold chamber & hot chamber
CastleKEY is available in two dedicated and specific versions depending on the technology: for cold chamber (Aluminum, Magnesium, Brass, Zinc) and hot-chamber processes (Zamak, Magnesium). Each version makes different optimization profiles available, dedicated to specific kinds of components: thin-walled, structural, aesthetic casting, as well as micro or custom components.
Cold chamber & hot chamber
CastleKEY is available in two dedicated and specific versions depending on the technology: for cold chamber (Aluminum, Magnesium, Brass, Zinc) and hot-chamber processes (Zamak, Magnesium). Each version makes different optimization profiles available, dedicated to specific kinds of components: thin-walled, structural, aesthetic casting, as well as micro or custom components.
Aid for the Die Designer
CastleKEY takes into account the specifications of the selected HPDC machine both from the point of view of locking force and shot-end dynamic performances by drawing on the built-in database that contains hundreds of presses from all major manufacturers. The user can be provided with a customized and optimized database specifically built on the company’s machinery. CastleKEY verifies if the given machine can reach a pre-set parameter (i.e. pressure or speed) and automatically adapts the calculation to the actual behaviour of the current machine suggesting, if available, the best compromise.
Aid for the Die Designer
CastleKEY takes into account the specifications of the selected HPDC machine both from the point of view of locking force and shot-end dynamic performances by drawing on the built-in database that contains hundreds of presses from all major manufacturers. The user can be provided with a customized and optimized database specifically built on the company’s machinery. CastleKEY verifies if the given machine can reach a pre-set parameter (i.e. pressure or speed) and automatically adapts the calculation to the actual behaviour of the current machine suggesting, if available, the best compromise.
Presses’ actual modeling
CastleKEY takes into account the specifications of the selected HPDC machine both from the point of view of locking force and shot-end dynamic performances by drawing on the built-in database that contains hundreds of presses from all major manufacturers. The user can be provided with a customized and optimized database specifically built on the company’s machinery. CastleKEY verifies if the given machine can reach a pre-set parameter (i.e. pressure or speed) and automatically adapts the calculation to the actual behavior of the current machine suggesting, if available, the best compromise.
Presses’ actual modeling
CastleKEY takes into account the specifications of the selected HPDC machine both from the point of view of locking force and shot-end dynamic performances by drawing on the built-in database that contains hundreds of presses from all major manufacturers. The user can be provided with a customized and optimized database specifically built on the company’s machinery. CastleKEY verifies if the given machine can reach a pre-set parameter (i.e. pressure or speed) and automatically adapts the calculation to the actual behavior of the current machine suggesting, if available, the best compromise.
Aid for the Foundry
It allows for productivity improvement by supplying optimal injection parameters, slow and fast shot speeds and strokes, shot sleeve diameter, and furnace and die temperatures in order to maximize part quality and reduce setup times. The software helps to understand if a casting defect is due to the mold, the machinery or the process, and it suggests potential solutions. It increases and stabilizes casting quality over time (in terms of porosity and surface finishing). It also allows for reducing the influence of temperature and alloy composition fluctuations, as well as of other factors not under control. It helps to reduce die-wearing and soldering phenomena, frequently caused by poorly calculated and inadequate ingates.
Aid for the Foundry
It allows for productivity improvement by supplying optimal injection parameters, slow and fast shot speeds and strokes, shot sleeve diameter, and furnace and die temperatures in order to maximize part quality and reduce setup times. The software helps to understand if a casting defect is due to the mold, the machinery or the process, and it suggests potential solutions. It increases and stabilizes casting quality over time (in terms of porosity and surface finishing). It also allows for reducing the influence of temperature and alloy composition fluctuations, as well as of other factors not under control. It helps to reduce die-wearing and soldering phenomena, frequently caused by poorly calculated and inadequate ingates.
Simulation support
An important feature of CastleKEY is that it makes the core of CastleMIND technology available to anyone who designs molds and simulates them using any of the competitor software on the market. Verifying the correctness of the design of a mold before launching the filling and solidification simulation allows you to avoid unnecessary waste of time in simulation calculations of molds far from being sized correctly. That translates into significant time savings and a more reliable design, avoiding too late noticing obvious settings errors.
Maximum flexibility and operational simplicity
The optimization of the molds can take place by importing into the software the model geometries in STL format that can simply be obtained from any CAD. Nevertheless, CastleKEY can provide the same outputs also starting from weights, lengths, and dimensions manually detected from an actual casting using a gauge, a scale, and a meter. This feature makes the software particularly flexible, allowing it to be used directly in the foundry to analyze molds for which the geometry file may not be immediately available.
Simulation support
An important feature of CastleKEY is that it makes the core of CastleMIND technology available to anyone who designs molds and simulates them using any of the competitor software on the market. Verifying the correctness of the design of a mold before launching the filling and solidification simulation allows you to avoid unnecessary waste of time in simulation calculations of molds far from being sized correctly. That translates into significant time savings and a more reliable design, avoiding too late noticing obvious settings errors.
Maximum flexibility and operational simplicity
The optimization of the molds can take place by importing into the software the model geometries in STL format that can simply be obtained from any CAD. Nevertheless, CastleKEY can provide the same outputs also starting from weights, lengths, and dimensions manually detected from an actual casting using a gauge, a scale, and a meter. This feature makes the software particularly flexible, allowing it to be used directly in the foundry to analyze molds for which the geometry file may not be immediately available.