Integration of Coupled Casting and Structure Simulation into the Development Process for Magnesium Die Castings

摘要

Simulation is an important tool in the different phases during development. It is used in the early. purelyrnvirtual development phase as well as in later production and final test phases. respectively. to analyse and solve issues ofrnthe components.rnTo simulate the structural behaviour one needs. besides the design. also the material properties of the component. Thernquality of the simulation is improved by an advanced characterisation of the material. Dimensioning and structure simulation ofrndie cast components are usually based on material properties that were derived from separately cast specimens. Actually.rndue to the process parameters the properties of die cast components could differ from those of specimens. One reason isrnthat die casting conditions may vary locally leading to different morphological characteristics. defect size and defect type inrncomplex components. The properties could vary depending on thickness. distance to injection location. and between castingrnsurface and centre of respective cross section.rnIt is explained in this paper that Takata-Petti and Calcom ESI found a way to couple die casting and structuralrnsimulation.By doing so. the influence of the die Magnesium alloy castings quality (gaseous entrapments. shrinkage cavities.rnand layering) on the component strength is considered. The integration of this method into the development process isrndescribed and the resulting improvements are explained. The results of the investigations about the interaction of thernmorphological characteristics of the cast material of a steering wheel and its material and component properties are used tornconfirm the method.