The benefits of using Flow 3D™ simulation
software are illustrated by our redesign of an
electrical switch frame for an aerospace
application. The switch, approximately 1 ¼” x 1”
x 1/2” in size, had a large number of defects
and a high scrap rate when produced by a
different manufacturer. We used our simulation
capabilities to pinpoint the defects caused by
porosity problems plaguing the part in two
locations: the plate and the chimney.
Using Flow 3D™ simulation software we analyzed
the flow behavior for the switch, which is cast
from A380 aluminum. With such a small
part, early solidification is a problem due to
the rapid cooling in thin sections. If flow jets
across the part and back, the fluid has more
time to cool and create entrapped air. It is
best to have the hottest liquid coming in last.
With this in mind, we were able to test a number
of ideas and create a design that minimized the
potential for problems and maximized the process
window. For more details on this design
success, visit:
http://www.flow3d.com/case-studies/case-study-littler.html
Littler Diecast Corporation
P.O. Box 96
500 West Walnut Street
Albany, Indiana 47320
