A high percentage of casting defects in jobbing foundries can be attributed to low compatibility between part requirements, tool/method design and process capabilities. These three must be optimized in integrated manner to achieve the desired quality at the least cost without shop-floor trials. For this purpose, we present a scientific approach comprising method design, process simulation, quality evaluation and cost estimation. Simulation results are evaluated using three quality indices: mouldability, fillability and feedability. Costing elements include tooling, material and process. An industrial case study is presented to illustrate the entire approach. Its greatest benefits are obtained during part design, when it is easy to make changes to ensure high compatibility between various parameters.
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