4 Designs Simulated in Parallel
Around 200 Core Hours
PRISMADD Japan is the joint-venture between Yamaichi Special Steel which has 80 years of knowledge on special steel and offers heat treatment, precision machining and precision measurement, and PRISMADD group which offers the progressive AM technology. PRISMADD Japan’s goal is to develop and manufacture next-generation products for aerospace, defense, automotive, energy, and medical industries.
As there is a high demand for additive manufacturing in the automotive mold market for conformal cooling channels design, there were a number of goals in this case study. These objectives included, but were not limited to, achieving faster mold prototyping, production lead time reduction, casting/injection cycle time reduction, and producing higher performant molds.
In order to evaluate the mold’s cooling channel performances directly at the design stage for closed-loop design, PRISMADD turned to CAE to reduce developmental costs and overheads.
Carrying out the design process for additive manufacture requires knowledge in many fields. While most jobs can be completed digitally by one person, an engineer is responsible for all stages of product development; innovative part design, topology, optimization, mechanical and thermal validation, industrialization, product preparation, and so on.
Large amounts of hardware and software are naturally needed to carry out these tasks, and shifting between each can be troublesome. By using SimScale, PRISMADD Japan was able to keep simulation parameters and easily swap the geometry for different design iterations, in turn allowing for direct design validation. Moreover, the cloud-based platform allowed the team to easily collaborate on one project.
The design of conformal cooling channels requires a lot of iterations, and often project and production lead times are very short. PRISMADD Japan needed an efficient time-dependent simulation, and a smart method of performing a CFD analysis of the metal and cooling water flow to gain results that would lead to the next stage of the development process−SimScale provided this. PRISMADD Japan continues to work with SimScale on additional design tests and evaluations.
With the Simscale Team, we could make a simplified simulation model simulating the injection and cooling time with heat flux. The simulation is not 100% accurate with reality but represents kind of the “worst-case scenario”, which was perfect for our needs.
If you would also like to virtually test your design with CFD or FEA in the web browser, discover the SimScale plans or learn more about the platform’s features.