The competitive situation in the automotive industry forces the car manufacturers to shorten their product cycles. Therefore the development speed has to be increased. This is why simulation techniques are gaining an increasing role in the product development instead of time-consuming validation testing. But reliable simulation results can only be achieved, if the simulation models consider all essential model parameter and boundary conditions. Especially in the case of crash simulation, big differences between simulation result and validation testing are found. The reason might be the disregarding of the manufacturing process and the according assumptions that a part has a homogeneous material behavior and no residual stresses. Both are unrealistic for castings. Using the example of a GPS bracket, manufactured in a high-pressure die casting process, the possibilities in defect prediction through casting process simulation are demonstrated. Additionally a way is shown, to transfer casting defects into a quality map, which describes the local durability of the casting. This quality map can be transferred to the FE-mesh for crash simulation and allows a more accurate calculation.
Integration of casting simulation into crash simulation
Integration der Gießsimulation in die Crashsimulation
2002
6 Seiten, 5 Bilder, 4 Quellen
Aufsatz (Konferenz)
Englisch
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