Digital twins and simulation are revolutionizing the foundry industry by providing advanced tools that improve the efficiency, quality and sustainability of production processes. Some of their main advantages and application examples:
1. Production Process Optimization
Defect Reduction: Simulation makes it possible to foresee and correct defects such as porosity, cracks and shrinkage before actual production, minimizing rejects and rework.
Quality Improvement: By optimizing process parameters and operating conditions, higher quality parts can be produced consistently.
2. Cost and Time Savings
Reduction of Physical Prototypes: Digital twins allow testing and adjusting designs virtually, reducing the need to build multiple physical prototypes.
Reduced Development Time: The ability to quickly simulate different scenarios accelerates the design and development process, bringing products to market faster.
3.Sustainability and Energy Efficiency
Material Usage Optimization: Simulation helps determine the optimal amount of material needed, reducing waste.
Energy Efficiency: By optimizing casting processes, energy consumption can be reduced, contributing to more sustainable practices.
4. Predictive Maintenance
Failure Prevention: Digital twins can monitor machine and equipment conditions in real time, predicting failures and scheduling preventive maintenance, reducing unplanned downtime.
Increased Equipment Lifetime: By efficiently managing maintenance, the useful life of machines and equipment can be extended.
5. Improved Decision Making
Advanced Data Analytics: Digital twins collect and analyze data in real time, providing valuable information that facilitates informed, data-driven decision making.
Scenario Simulation: The ability to simulate different conditions and scenarios allows you to evaluate the impact of decisions before implementing them in the real world.
6. Innovation and Flexibility
Development of New Alloys and Processes: Simulation allows experimentation with new alloys and processes without risk, fostering innovation.
Adaptability: Digital twins facilitate rapid adaptation to changes in product designs or market demands.
7. Integration and Collaboration
Improved Collaboration: Simulation tools and digital twins enable better collaboration between design, engineering and production teams, improving communication and reducing errors.
Integration with other Technologies: Digital twins can be integrated with other emerging technologies such as artificial intelligence and the Internet of Things (IoT), further enhancing their benefits.
Application Examples
Mold Optimization: Simulation of mold filling and solidification to ensure optimal design.
Thermal Analysis: Simulation of thermal behavior during casting to control cooling and minimize internal stresses.
Mechanical Properties Prediction: Simulation of the impact of different casting parameters on the mechanical properties of the final product.
Simulation and digital twins, a competitive advantage
In summary, simulation and digital twins provide a significant competitive advantage in the foundry industry by improving efficiency, quality, safety, sustainability and innovativeness.
At Insertec, we have a Calculation Engineering department. It is responsible for performing structural, fluid-mechanical and thermal simulations of equipment and/or sub-assemblies to optimize their design and operation under various conditions. Their work is essential for innovation and continuous improvement in our engineering projects.