CAE techniques from CAD to lifetime prediction are essential support tools to the design process for automotive castings, particularly for power train parts. Substantial savings in development time, costs and risks gained by an increasing grade of integration between the different CAE tools, have been reported. Technical effects are clearly visible as well: filigree casting structures, fulfilling increasing demands for mechanical durability, have been created. But with more and more sophisticated designs, the risk of failure during durability tests or in the field, caused by wrong simulation results, increases as well. This point is also reported. This might be boosted by lack of focus on manufacturing process specifics within the design process chain. This contribution aims to clarify, how specifics like residual stress in castings or an inhomogeneous distribution of mechanical properties can be found by manufacturing process simulation, and be integrated with the CAE tools which support the casting design process. As example, the casting process of a FORD V6 iron engine block was simulated. In detail, the phase distribution being formed during solidification and further cooling were simulated, and based on this the distribution of mechanical properties like the Young's Modulus was calculated and prepared to be transferred to FE analysis. Also based on the ''thermal history'' of the casting, the residual stress distribution was simulated and then transferred from the structured mesh which is used for the casting simulation to an FE mesh for the simulation of stress rearrangement during machining of the block.
Integration of manufacturing process simulation into the process chain
Integration der Fertigungsprozeßsimulation in die Designprozeßkette
2002
6 Seiten, 9 Bilder, 2 Quellen
Aufsatz (Konferenz)
Englisch
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