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Comparative study of casting simulation softwares for future use during early stages of product development
Jönköping University, School of Engineering, JTH. Research area Materials and manufacturing – Casting. Jönköping University, School of Engineering, JTH. Research area Product Development - Simulation and Optimization. Scania CV AB.
2015 (English)Independent thesis Advanced level (degree of Master (Two Years)), 20 credits / 30 HE creditsStudent thesis
Abstract [en]

Within industrial product development processes there is an increasing demand towards reliable predictions of the material behavior, which aims to promote a property driven development that can reduce the lead times. The implementation of simulation based product development with integrated casting simulation may enable the design engineers to gain an early understanding of the products with relation to castability, and orient the subsequent design refinement so as to achieve the desired mechanical properties.

This work investigates the suitability of three commercial casting simulation softwares –MAGMA 5.2, NovaFlow & Solid 4.7.5 (NFS) and Click2Cast 3.0 (C2C)–, with respect to the needs of design engineers, such as prediction of shrinkage porosity and mechanical properties with relation to the design. Simplified solidification simulations suitable for this stage were thus performed for three high pressure die cast components with different geometrical constraints.

The comparability between the solidification and cooling behaviour predicted by the three softwares was studied, and showed that a reasonably good agreement between predicted solidification times by MAGMA and NFS could be obtained, albeit not between predictions by MAGMA and C2C. Predictions by the three softwares of the hot spot/porosity areas showed to have a good agreement. The calculation times by each software were compared, and MAGMA was seen to have the best performance, yielding significantly shorter times than NFS and C2C.

The results obtained were also compared to experimental investigations of porosity, microstructural coarseness, and mechanical properties. There was a good agreement between the predicted hot spot areas –i.e. areas in the geometry that solidify last– and the findings of porosities in the actual castings, meaning that solidification simulations might be able to provide important information for the prediction of most of shrinkage related porosity locations that are related to the casting geometry. However, the lack of a detailed knowledge at the design stage of the casting process limits the possibilities to predict all porosities.

The predicted microstructure and mechanical properties by MAGMA non-ferrous were seen to have a good agreement in trend with the experimental data, albeit the predicted values showed large differences in magnitude with the experimental data. Although, the MAGMA non-ferrous module was not developed for HPDC components, it was interesting to study if it could be applied in this context. However, the models seem to need adoption to the HPDC process and alloys.

In conclusion, with a limited knowledge of the manufacturing parameters, simplified solidification simulations may still be able to provide reasonably reliable and useful information during early development stages in order to optimise the design of castings.

Place, publisher, year, edition, pages
2015. , 97 p.
JTH research report, ISSN 1404-0018 ; ISSN 1404-0018
Keyword [en]
Casting simulation, aluminium, high pressure die casting, mechanical properties, casting defects, porosity, microstructure, SDAS, benchmark study
National Category
Manufacturing, Surface and Joining Technology Metallurgy and Metallic Materials
URN: urn:nbn:se:hj:diva-28023ISRN: JU-JTH-PRU-2-20150027OAI: diva2:855951
External cooperation
Scania CV AB
2015-08-12, 16:43 (English)
Available from: 2015-10-07 Created: 2015-09-22 Last updated: 2015-10-07Bibliographically approved

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JTH. Research area Materials and manufacturing – CastingJTH. Research area Product Development - Simulation and Optimization
Manufacturing, Surface and Joining TechnologyMetallurgy and Metallic Materials

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