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Flow Animation

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:
  Littler Diecast Corporation
P.O. Box 96
500 West Walnut Street
Albany, Indiana 47320
  Phone: 765.789.4456
FAX: 765.789.4112

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