Castle MIND

Castle Mind is a simple and straightforward application. It is what in the software language is called an expert system, i.e. a program capable of combining a calculation engine with one or more experience databases. In this way, Castle Mind guides the choices of the foundry and the mold maker from the beginning of the project when the degrees of freedom are multiple, and the costs of modifications are least.

Castle Mind is available in two dedicated and technology-specific versions: Castle Mind CC for cold chamber processes (Aluminum, Magnesium, Brass, Zinc) and Castle Mind HC for hot chamber processes (Zamak, Magnesium).

Castability analysis

The castability analysis allows the user not to waste time on unnecessary simulations. And above all, not to waste time and resources on multiple mould trials.

Castle Mind is an innovative design tool that evaluates the mould design, optimizes the casting parameters through the PQ2 diagram and suggests the optimal ingate sizes and the modifications to be made to achieve the casting with the requested quality and performance.

  • Direct file import of a wide range of CAD formats (Step, Parasolid, Iges, Solid Works, Solid Edge, Catia and many others)
  • Automatic reading of geometry data (volumes, thicknesses, frontal areas)
  • Model preparation in one minute, calculation in one second
  • Optimization of the mould design and its performance
  • Practical interactive tips

Castle Mind offers a complete modelling of the die casting equipment: the machine is described not only by its size or clamping force, but also by the dynamic features of the injection unit. Accelerations, decelerations, delays, and the state of wear of the machines are taken into account. The foundry can be provided with a customized database of its machines that may differ from the standard one supplied. Castle Mind verifies whether or not the indicated machine is able to reach a preset parameter (i.e. pressure or speed) and automatically adapts the calculation to the actual behaviour of the real machine, suggesting, if available, the best compromise.

For die designers

Castle Mind provides the ability to:

  • Calculate the optimal number of cavities in relation to the selected DCM.
  • Optimize the size 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 die casting machine.
  • Supply information on how to make the die 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.
  • Calculate the optimal plunger diameter  and gets the casting parameters for the given die/machine combination.
  • Automatically compile the machine parameters datasheet (injection strokes, plunger speed and pressure) as a guideline to be sent to the foundry

For foundry engineers

Castle Mind enables to:

  • optimize production: providing optimal injection parameters, slow and fast shot speeds and strokes, shot sleeve optimal filling ratio, 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 die, the DCM or the process and indicates potential solutions.
  • increase casting quality (also in terms of porosity and surface quality) and, more importantly, to maintain it extremely stable over time.
  • 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.