Optimum Engine Component Design and Process Validation Using Metal Casting Simulation Tools 2001-01-1037
Over the past several years, metal casters have made a strong commitment to better process understanding, optimization, and shortened lead times through the use of advanced technologies. Computer Aided Design and Engineering tools (CAD/CAE) are extensively utilized in the industry. Castings and production equipment are designed at the computer and these models are used as input into simulation tools. The machined and assembled components are checked for work load, strength and noise ratios. Furthermore, raw part characteristics, resulting from the production process, which have a big influence on the achievable quality, can be simulated before the final production process is released.
Filling and solidification patterns, outside cooling effects, cycle times, residual stresses, and microstructure can be simulated and evaluated. Doing simulations of alternative casting processes allows for the choice of the right production process to meet component design requirements.
This paper provides an example of how casting process simulation can be used, up front, to optimize the design of an automotive engine component, to develop the appropriate tooling designs, and to validate the selection of casting process parameters for optimum production of the part.