Core Making

Sand Core Engineering

Core making can be challenging.  Both sand and air flow, within the tooling, are essential for making a good core.  Arena-flow is not just a process model, but rather a fundamental approach to computing the sand flow and air flow physics of core making.  Thus, it is not applicable to only one process, but has been successfully applied to a variety of core making technologies.  Learn how you can apply the Arena-flow Sand Core Engineering Technology for your process:
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Cold-Box

If you're utilizing a cold-box process, you're probably very interested in productivity.  Arena-flow has interfaces specifically designed to enable the cold-box foundry to optimize their processes resulting in minimal scrap, binder loadings, amine or SO2 usage and cycle times.  Cold-box sand core engineering physical models include:

  • air flow modeling
  • transient amine curing
  • transient SO2 curing
  • core fill and miss-fill prediction
  • core density variations
  • tool wear prediction
  • resin wipe-off prediction
  • sand particle size distribution
  • multiple sand types, and mixtures
  • sand flowability (binder effects)
  • discrete vent models
  • magazine performance and rat-holing
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Shell Sand

If you're a shell foundry, then you probably have other concerns.  Shell tooling is different than cold-box tooling.  Venting may be limited, and the air flow in hot shell tooling is vital to ensuring complete and uniform core filling behavior before the sand begins to harden.  Shell sand core engineering physical models include:

  • transient air flow during core filling
  • sand particle size distribution
  • multiple sand species
  • core fill and miss-fill
  • core density variations
  • tool wear prediction
  • sand flowability
  • discrete vent models including: circular vents, slit vents, parting line venting, vent clogging, etc.
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Warm-box, Hot-box, Inorganics, ... 

Arena-flow has been used to simulate, understand and optimize a variety of other core making processes.  While the flowability or "stickiness" of these binder systems can differ, Arena-flow includes a custom flowability model which enables you to compute the complex, core-filling behavior.  Advanced sand core engineering physical models include:

  • transient air flow during core filling
  • sand particle size distribution
  • multiple sand types and mixtures
  • tool wear prediction
  • resin wipe-off prediction
  • custom sand flowability
  • discrete vent models
  • magazine performance and rat-holing
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Tooling Design

Arena-flow is not just useful to foundries, but also for tooling suppliers.  If you are a tooling vendor, then you likely design and manufacture tooling for a variety of customers employing a variety of core making processes.  At the same time, your customers are probably asking you to take on an increasing level of design responsibility, as they have reduced their internal expertise over the past few years.  All of the above sand core engineering physical models are available to tooling suppliers.  Tooling suppliers, however, typically have different reasons for running Arena-flow calculations.  These include:

  • meeting or exceeding OEM requirements
  • eliminating trial-and-error in the design process
  • creating a good core on the first blow
  • designing optimized tooling
  • designing long-lasting tooling with minimal wear
  • differentiating themselves from the competition

Case Studies

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    Core Scrap Reduction

    Cost savings are obtained by reducing the scrap rate for a cylinder block water jacket core.

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    Casting Scrap Reduction

    Cost savings are obtained by reducing the scrap rate for cam shaft castings produced by two shell mold halves.

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    Cycle Time Optimization

    Cost savings are obtained by reducing the cycle time for a precision sand cover core.

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    Capital Cost Savings

    Significant capital cost savings are obtained by optimizing each core in a core package.

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Still not convinced?  Give us your most challenging core and see what we can do.

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