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An innovative integrated CAE approach for the design and optimization of

foundry moulding boxes

Conference Paper · November 2014

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 An innovative integrated CAE approach for the design and optimization
of foundry moulding boxes

G.L. Di Muoio1, G. Bertuzzi, J. O. Frandsen

Casting Technology, Global Castings A/S, Diplomvej 373N, Kgs. Lyngby, 2800, Denmark
1
E-mail: [email protected]

Keywords: Process Optimization, Process Simulation, Moulding Box Design, Computer Aided Engineering,
Product Development

Abstract
Moulding boxes are a critical tool in production of large cast items because they are involved in and affect
most of the production steps in a foundry. Optimization of moulding boxes design allows to harvest
significant savings in terms of sand consumption and possibly increase capacity by simplifying handling and
shortening production times.

Optimization of such a design is not a trivial task. This is due to the many interactions with other production
tools and to the need to check compliancy with the different requirements and constraints coming from
each production step.

In this paper, a novel approach to the design of moulding boxes is presented with the objective to simplify
the design workflow and optimization process of customized moulding boxes with the aid of CAE tools.
Additionally, tools such as values stream mapping and interface diagrams are introduced to improve the
management of the design process and optimize the usage of CAE tools.

Results shows that significant savings can be harvested, but that optimization generates an increase in
complexity of the moulding boxes that can only be handled thanks to the newly introduced design
approach where CAE tools are smartly used and integrated in design workflow.

Introduction
Moulding boxes represent a critical tool in the casting process because they are involved in and affect all
the production steps: moulding, handling and turning, assembly, pouring and shake out. However, in
traditional jobbing foundries moulding boxes are used in standard shapes and dimensions mainly to
provide mechanical support for the sand mould and not much attention is paid to their design or
optimization. The use of standard dimensions is due to the high product mix that generates the need to be
able to produce different parts in the same moulding box.

On the other hand, the continuous pressure on the foundries for costs reduction makes necessary a new
approach to the process design where tools and costs are minimized maintaining or improving the degree
of quality of the casted items. This new approach matches mainly the requests of foundries producing large
sized castings (5 to 30 tons) and that typically handle few items in medium and large series with stringent
requirements in terms of dimensional tolerances and mechanical properties. The use of standard moulding

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An innovative integrated CAE approach for the design and optimization of foundry moulding boxes 1
boxes for large size items leads to a high usage of sand which increases the price of the parts and puts
strain on the sand transportation systems, limiting the production capacity of the factory. Finally, the
casting of large cast iron sections in thick sand moulds generates long cooling times which increases the
number of moulding boxes needed and the shop floor space usage in the foundry further limiting
production capacity and increasing the production cost.

An optimized design of the moulding boxes can allow significant reduction of weight and price of the tools,
a lower amount of sand used in the production process (Figure 1), easier handling, shorter production
times and, if properly designed, final casted parts with improved quality. However, optimizing the design of
such a production tool is not an easy task. This is due to the many interactions with other production tools
and equipment and to the different conditions to which the box is subjected in the different production
steps (mechanical, thermal, chemical, etc...).

In this paper, a novel approach to the design of moulding boxes is presented with the objective to simplify
the workflow of the design and optimization process of customized moulding boxes with the aid of CAE
(Computer Aided Engineering) tools. The moulding box is seen as new product to be developed and the
design process is based on the analysis of the interfaces and interactions between the moulding box and
other tools, of a set of requirements coming from the different production steps and of a set of economic
constraints.

CAE tools are needed in order to shorten the design time and lower final cost of the moulding box,
therefore maximizing the revenues (Figure 2) [1,2]. The geometries of the moulding boxes are developed
from concept to detailed design using 3D CAD software. Failure modes are checked by the use of
preliminary, self-developed hand calculations and finally with commercial Finite Elements software both for
the moulding boxes and the casted parts.

Figure 1. Sand saving concepts: a) standard moulding box, b) standard box with sand savings c) optimized
moulding box.

Figure 2. Effects of CAE tools on product lifecycle [1,2].

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An innovative integrated CAE approach for the design and optimization of foundry moulding boxes 2
The innovative approach is used to re-design and existing moulding box and the results are then compared
with a classic design. Results confirm that significant savings can be harvested by using this procedure both
in investment costs and variable costs. On the other hand, the use of CAE tools on an advanced level is
necessary in order to handle the increased complexity and the many design constrains.

Methods
Traditional Design Methodology
In traditional design methodology tools are developed in a sequential way as it can be seen in Figure 3.

The main drawbacks of this process are:

- Each step is handled independently with no overall view, it is therefore difficult to reach an overall
optimized design
- Designers responsible for a step do not normally communicate with designers of other steps
(especially if steps are not adjacent) since the process does not require this
- It is very inefficient from a time optimization point of view because the process is sequential, and
one step is started only when the previous is completed
- Problems arising in one step are ‘taken as they come’ and designers try fix them within they
knowledge areas and without challenging constraints, this results typically in delays and cost
increases
- Initial steps decisions heavily hinder innovation in subsequent steps, since it is extremely difficult
and expensive to make changes to an already frozen design step

From a CAE usage point of view. We note that CAE is typically used only in some steps and in a sequential
way and therefore not exploiting the full potential offered. For example, PLM system is not used to design
and maintain 3D documentation of production tools. 2D drawings are preferred mean of exchange
between steps this slows down significantly simulation capabilities where good quality 3D geometries are
instead needed.

Figure 3. Traditional design methodology.

New Design Methodology

Based on methodology typically used for development of new products [3] a new desing process is
introduced.

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The newly introduced desing process (Figure 4) starts by defining a clear set of requirements coming from
the customer. Then, two main iterative desing loops are used to initially define the design concept and then
to finalized the detailed design.

The first loop is iterated until all the stakeholders approve the desing concept and no more changes are
needed to the the concept. The second loop is iterated until test and 0 series are completed succesfully.

Whitin the detailed desing phase one more iteration loop is present (Figure 5). In this loop, the necessary
calculations and simulations are performed and the design is optimized until all the constraints coming
from the customer requirements are satisfied.

Figure 4. Overall view of new design process.

Figure 5. Schematics of detailed design phase of the new design process.

Value Stream Mapping

In order to define a clear and as complete as possible set of requirements, a value stream mapping of the
process is carried out and for each operation the tool interfaces and requirements are listed (Figure 6).

It is important to point out that process mapping shall be carried out a team effort involving both design,
production and management team [4]. This allows not only to reduce the risk of missing critical interfaces
or requirements but also create a common shared understanding of the tool requirements for the different
stakeholders [5].

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 Figure 6. Requirements and interfaces identification trough value stream mapping.

Interface Diagram

Tools are grouped in systems, where a system represents a units that bears a specific function. For example
the moulding system groups all the tools needed to manufacture a complete mould.

Interfaces between tools are then identified, classified and graphically visualized (Figure 7).

Figure 7. Interface diagram for a moulding box. This diagram helps to visualize all the interactions
between the moulding box and the other production tools.

Design work is then started on each of the tools as soon as interfaces are agreed upon and resources are
available (Figure 8). Design teams will keep interfaces unchanged unless there is a problem to meet a
specified requirement or goal. If an interface requires modification, the involved design responsibles and
affected stakeholders will review and eventually approve the change if feasible.

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 Figure 8. Planning overview of different systems designs.

Table 1 shows how CAE tools are used in the different design phases and integrated in the design workflow.
It can be seen, for example, how 3D modelling is critical to all phases, from concept design (to visually
evaluate the solution and speed up the review process), to detail design (where 3D models are used for
simulations) and in documentation and testing (where 2D are generated from 3D). Finally PDM systems are
used to maintain and track changes to the tools over their lifecycle.

Table 1. The role of CAE tools in the different phases of the new design process

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Results
Design Process Comparison

Table 2 shows how critical aspects of the design process differ in the two proposed methods. For example,
we can notice that 3D design competence, previously outsourced, is now handled in house to allow for
better integration and communication [6]. Additionally, overall competences of the staff were increased to
be able to be able to use CAE tools in an advanced manner.

The level of innovation achieved is much higher since now the work on different tools is carried out in
parallel and decision on design or interface changes are done based on a total cost evaluation, not just in
respect to one production step.

Documentation process followed naturally and was speeded up by the in house availability of 3D models.

Finally, the process helped to foster innovation by having a quantitative assessment of the ideas (based on
calculation, simulation or tests) as compared to a qualitative assessment criteria that was often used
previously.

Table 2. Comparison between the caracteristics of a classic sequential design process and the new CAE
integrated design process.

Mouldbox Comparison

The design that resulted from the application of this process to a standard tool like the mouldbox show a
general increase in complexity. In Figure 9 we can see general level of complexity of a mould box and how it
increases when from a standard design we go towards optimized design. Such complexity could not have

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been handled optimally only with the use of old simple 2D drawing softwares and without a management
process that focused on clear requirements and interfaces defintion.

Figure 9. Example of standard moulding box (on the left), sand saving moulding box (at the centre) and
optimized moulding box (on the right). 3D cad models are build and used as starting point for advanced
software simulations. (Some parts have been hidden for commercial reasons)

Table 3 summarizes the main key performance indicators for a tool like a moulding box. It can be see how
the steel amount used can be reduced in an optimized moulding box, but the percentage of custom plates
increases drastically as well as the number of different BOM item. This results in a higher cost per kg of
steel (due to increased amount of welds and custom plates) in the optimized moulding box but in a lower
final total cost due to the material savings achieved.

Also we can see how sand usage quantity was drastically reduced, as well as the effect on the cost of the
produced item.

Table 3. Overview of key performance indicators for the three different moulding boxes designs (values
relative to standard moulding box).

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 Conclusions
A new design methodology that heavily relies on CAE tools as well as on an improved management of the
different systems and their interaction was implemented. The results was an increased capability to handle
complex design in an easy way and a significant savings achieved both in investment and variable costs.

Acknowledgments
We wish to thank the management team of Global Casting A/S, for supporting such an innovative initiative,
as well as all the people involved in the project from the design team, to project management office and
factory floor for the hard work that made this a successful implementation.

Literature
[1] J. Mohammed, J. May, A. Alavi, Application of Computer Aided Design (CAD) In Knowledge
Based Engineering, Proceedings of The 2008 IAJC-IJME International Conference, ISBN 978-1-
60643-379-9.

[2] Giesecke, F., Mitchell, A., Spencer, H., & Hill, I. (2003). Technical drawing. Upper Saddle River,
NJ: Prentice Hall.

[3] Karl T. Ulrich and Steven D. Eppinger, Product Design and Development, 2nd Edition, Irwin
McGraw-Hill, 2000.
[4] P.G. Smith, Cross-Functional Design Teams, ASM Handbook, Volume 20, Materials Selection
and Design, 1997, pp 49-53.
[5] Manuel E. Sosa, Steven D. Eppinger, Craig M. Rowles, Are Your Engineers Talking to One
Another When They Should?, November 2007, Harvard Business Review, Page 133, hbr.org.
[6] D.I. Cleland, Field Guide to Project Management, Concurrent Engineering (Chapter 32), John
Wiley & Sons, 1998.

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