Castle Mind

Castle Mind is an innovative tool design and a powerful expert system which evaluates the casting design, optimizes the casting machine parameters through the PQ2 calculations and suggests the optimal gating size and the optimal process parameters.

  • Direct file import from a variety of CAD systems (including Step, Parasolid, IGES, Solid Works, Solid Edge and Catia and many others)
  • Direct data input of the casting geometry (volumes, thicknesses, surfaces)
  • Model preparation in a minute with the optimization calculation in a second.
  • Optimization of die design and performance
  • Interactive practical suggestions

For die makers:

Castle Mind provides the ability to:

  • Optimize the dimension and shape of the gates in relation to the type and quality of the planned cast, number of cavities, type of alloy and size of moulding machine.
  • Supply information on how to make the mould perform to its maximum potential  (through PQ² diagram) and according to the kind of equipment installed and the operating conditions faced
  • Help decide whether it is necessary to thermo regulate or raise the temperature of the die. The system optimizes the plunger diameter  and gets the moulding parameters for the given mould/machine combination.
  • Automatically compile the machine parameters datasheet (injection strokes, plunger speed and pressure) as a guideline to be sent to the foundry.

For the foundry:

The machine clamping force is much higher than needed: it’s possible to reduce machine tonnage if necessary.
The filling ratio is good if necessary, try to reduce the plunger diameter, increase the counterbushing length.
The gating size is just enough but die erosion or finishing defects can arise – try to increase gate area. If possible, try to increase die temperature.
The plunger size is quite good.
The second phase static pressure is good: to achieve better results, try to decrease plunger diameter.
The allowed plunger speed is good enough.
Decrease the fast shot speed.

Castle Mind enables to:
  • optimize production: providing optimal injection parameters, slow and fast shot speeds and strokes, shot sleeve diameter, furnace and die temperatures in order to maximize part quality and reduce setup times.
  • facilitate objectively establishing if a casting defect is due to the mould, the machinery or the process and indicates potential solutions.
  • increase casting quality (also in terms of porosity and quality finishing) and, more importantly, to maintain it extremely stable over time being influenced in only a small way by temperature and alloy composition fluctuations, in addition to other indeterminable factors.
  • reduce mould erosion and metallization phenomena, frequently caused by poorly calculated and inadequate riser gates.
  • reduce setup costs related to casting modifications needed due to defects detected (i.e. gates editing) during the sampling process.