Located just outside of Grand Haven, Michigan, EPS Industries produces mission-critical investment castings for the military, pump and valve, transportation, and medical industries. Their success is built on continuous improvement: every part and process are repeatedly evaluated to ensure that they turn around the highest quality parts as quickly as possible.
When one of their high-production lever castings was returned by the machine shop for occasional shrink on a critical surface, they knew that there must be a better way to make that part. Engineers at EPS tested some modifications to the layout of parts on the sprue, which yielded some improvements, but about 25% of the parts still showed shrinkage after machining.
EPS reached out to engineers at MAGMA to simulate the lever castings and investigate further improvements. The initial simulations showed that despite a relatively straight-forward geometry, the casting had two separate hotspots that are somewhat merged (shown below). Being unable to determine whether there’s two separate hotspots or just one made the gate design challenging.