Mednarodno 48. Livarsko posvetovanje / International 48th Foundry Conference 1 R.Radiša 1 , S.Marković 2 , J. Pristavec 3 , V.Kvrgić 4 , S. Manasijević 5 USE OF CAE TECHNIQUES IN VIRTUAL DESIGN OF METALCASTING TECHNOLOGY-SAVINGS IN SERBIAN FOUNDRIES Abstract: Information technology and virtual manufacturing of castings enabled shortening the time to develop a product, as well as high quality castings fabrication at first attempt, what can be the crucial contribution in achieving the increased engineering adequacy and economic competitiveness of foundries in Serbia. Matching the global market demands, increasing engineering abilities and economic efficiency will necessitate the rationalization and optimization of castings manufacturing. Concerning the productivity, the amount of waste and energy consumption per 1kg of casting, the usage of virtual manufacturing for castings fabrication have a great impact on foundries operating in Serbia. Beside some theoretical considerations numerous practical examples have been presented in this paper. Key words: virtual manufacturing, simulation, metal casting, savings. 1. GLOBAL CASTING INDUSTRY TODAY This vital industry is faced today with many challenges. On the one hand, it has to meet the rising customer expectations regarding quality assurance, shorter product lead time, smaller series, lower and more competitive prices. On the other hand, foundries are loosing pace with fast technological and management changes in other manufacturing sectors. One example is the increased use of NC machines for finishing operations requiring dimensionally stable castings with uniform surface hardness necessary to avoid cutting tool damage. By comparing present situation with the one of a decade ago, it can be seen that most countries are decreasing the number of foundries, while compensating this by respective increase in the production volume. On the other hand, adopting the just-in-time product delivery philosophy in assembly in order to decrease storage costs, obliges foundries to deliver castings just-in-time (often on a specific date, time and location). There is constant pressure from regulatory bodies in terms of energy conservation, environment protection, and occupational safety as an additional concern. Therefore, many of the most important customers, especially in the automotive industry, have turned to long-term strategic partnership with a few well-established foundries, instead of previous short-term cost-based purchasing agreements with a larger number of foundries [1]. This means that, in order to survive, the foundries must offer dimensionally stable and sound castings, and ensure reliable delivery on time, especially in case of foreign customers. In order to satisfy customers without sacrificing profitability, foundry engineers have to model and control the casting process accurately, in order to achieve desired quality, and to optimize production volume without repetitive and prolonged shop-floor trials. One of the reasons for this situation is that considerably less research and development is invested in the casting industry compared to other production sectors. Therefore, although the process is 5000 years old, casting continues to be more of an art than a science. Figure 1. displays complexity of the problem to be solved in the process of producing a sound casting. 1 Radomir Radiša, M. Sc., LOLA institut, Belgrade, Serbia, tel. +38111/2547604, e-mail: rradisa@lola-ins.co.yu 2 Ph D Srđan Marković, M. Sc., Faculty of Technology and Metallurgy, Belgrade, Serbia, e-mail: srdjan@tmf.bg.ac.yu 3 Janez Pristavec, M. Sc., Exoterm-it, tel. +38642770730, e-mail: janez.pristavec@exoterm.si 4 Ph D Vladimir Kvrgić, M. Sc., LOLA institut, Belgrade, Serbia, tel. +38111/251303, e-mail: vkvrgic@lola-ins.co.yu 5 Srećko Manasijević, M. Sc., LOLA institut, Belgrade, Serbia, tel. +38111/2547604, e-mail: sreckoman@ptt.rs Paper is part of research realized on the project number 14026 and project number 19041 which is partially financed by Ministry of Science and technological develoment Republic of Serbia, cycle 2008-2010.