The next step in this technology is represented by a new product called OPTICast, the result of a collaboration between Finite Solutions and Altair Engineering. OPTICast uses mathematical optimization to guide the design process automatically.

With most casting simulation software, the user creates a design, runs a simulation, and then evaluates the results by plotting various output data to see if the results are acceptable. If not, a change in the computer model is made by the user, and another simulation is run. This is basically a "trial-and-error" approach. OPTICast, on the other hand, takes an initial process design from the user and then allows the user to specify which aspects of the design are allowed to vary and what the desired outcome is to be. For example, the user could specify that riser sizes are to be varied until yield is maximized while shrinkage porosity is held to a specified level. OPTICast will then run a series of simulations using the SOLIDCast package (from Finite Solutions), evaluate each simulation run, make a decision on its own about what to change in the process design, and then run the next simulation. This continues until the desired results are achieved. Thus, the foundry engineer can start the process, walk away from the computer, and come back later to view the optimum process design. This approach can maximize yield and minimize scrap with very little effort, reducing energy and material costs as well as lead times. Numerous in-foundry trials have resulted in up to 20% reduction in pour weight with equal level of casting quality. For more information contact Larry Smiley at 513-821-5220 or LSmiley1@aol.com and mention buyCASTINGS. Join buyCASTINGS.com and receive a 5% member discount on OPTICast software!