DESIGN & SOFTWARE CAPABILITIES
Part Modeling and CAM Software
TCDC uses the latest revisions of SolidWorks (preferred), Pro/E, and KeyCreator for part and tool modeling. TCDC also uses Gibbs CAM software to assist in CNC machine programming.
Cast Simulation Software
TCDC uses the SIMTEC cast simulation software. SIMTEC is a Finite Element Method (FEM) analysis tool that can simulate metal flow, temperature, cooling, residual stress, and part distortion. TCDC uses this information to enhance part and tool designs.
Metal Flow
SIMTEC stimulates liquid metal flow from the beginning to the end of a shot, allowing TCDC to predict the flow pattern across a cavity and the last spots to fill. This helps in the design of gating for best fill and in the placement of overflows and vents. The result is a more sound, less porous casting, that is also less prone to knit and inclusion defects.
Temperature/Cooling
Temperature control and even cooling can have big impacts on casting quality. TCDC does temperature simulations to identify hot or cold spots and assist in the design of a tool's water and hot oil systems
Stress/Distortion
Some part designs are prone to distortion during solidification and shrink - in fact, shrink distortion in the primary factor that limits the dimensional accuracy of a die casting, and sets the lower bound on NADCA precision tolerances. Our simulation software allows us to predict the extent of this distortion on any given product. Armed with this data, TCDC has intentionally built cavities to an inversely distorted shape, in order to compensate for the expected shrink distortion. This has allowed us to achieve tolerances considerably tighter than NADCA precision - without the need for a re-cut.
