Sequential simulation of casting and machining

Important results from the project

The object of this project is to link simulation of casting with simulation of machining to obtain more accurate properties in the final product. The target is to identify difficulty in sequential simulation for castings with added simulation of cutting machining in order to start a larger research project including the whole manufacturing sequence and verification of the stresses. It is when these two important steps in the production chain of a cast component are included that realistic assessment of the product verification can be done.

Expected long term effects

Linking of the two key elements in the production of castings by simulation is a great opportunity for the foundry industry. The use of the methodology will allow production of more optimized products, resulting in higher profit margins and less environmental impact. The idea is, in the future, being able to simulate the entire production chain to the finished component, and then apply the operating loads. This hypothesis testing will only be directed towards linking casting and machining in simulation.

Approach and implementation

Strategy for success in simulations of different processes of a products development is the transfer of information between the various simulations. It is important that the product´s status (e.g. stresses state) really comes in as the starting value in the next step in the chain. In the work the build up of the residual stresses will be studied. The project will be divided into four different work packages, WP. In parallel with these four activities project management and dissemination of information will take place. WP1 - Concept study, the possible transmission format for information from casting to machining simulation is examined WP2 - Simulation, artificial component is simulated during the various stages of the manufacturing process WP3 - Evaluation, the results from the simulations is evaluated WP4 - Methodology dissemination, an article is written with the goal of publication on an international conference