NCEMT engineers began by performing finite element analyses (FEA) and fracture analyses of both training and high-explosive projectiles.
While this would satisfy the Navy's requirements, the NCEMT took the problem a step further by using its Rational Product and Process Design |Mathematical Expression Omitted~ methodology to obtain information needed to eliminate any process problems, rather than just avoid them.
In the case of the cast projectile, NCEMT engineers used the CFD module to experiment with alternate operating parameters, such as superheat of the molten metal and various ingate and riser designs and casting orientations.
For example, the |Mathematical Expression Omitted~ software allowed NCEMT engineers to rotate casting models 360 degrees, cut models open to examine porosity, change display colors to dramatize temperature or other variations, change the background color, magnify sections of a model, and open up as many windows as necessary to compare and contrast different views and, if necessary, different castings.
To meet the Navy's requirements, NCEMT engineers combined the results of their design analysis and casting simulations and specified minimum fracture toughness and nondestructive evaluation criteria for flaw size.
For example, the NCEMT already has helped companies develop the process specifications needed to produce several components, including a large marine casting, an exhaust manifold and several automobile pistons.