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TITLE OF PAPER
University of Bologna
A multi-physics approach to model a Die Assisted Oil Quenching process
Giampaolo Campana, University of Bologna | Andrea Zanotti, Proterm S.p.A,
Quenching processes consist of a drastic cooling, from a high temperature, a nearly finished mechanical part in order to achieve the expected material performances. The rapid cooling changes material microstructures by typically enhancing mechanical properties but inducing distortions and residual stresses too.
The Die Assisted Oil Quenching (DAOQ) technique allows the heat treatment of a steel mechanical component though the use of a quickly cooled die, which applies a pressure on the part during the quenching. Through an accurate control of the cooling conditions, this process lay-out permits the reduction of distortions.
A challenging task is the modelling of the DAOQ process with the usage of a multi-physics approach including heat exchange, fluid dynamics, metallurgical aspects, volume variations and residual stresses prediction. The paper presents an investigation concerning a multi-physics model implementation of the DAOQ process. The simulated components were discs and rings characterized by specific diameter ratios. The tuning and validation of the model was achieved by comparing calculated displacements with real measurements.
Stress and deformation analyses on a HPDC component
The actual market requests high quality products and low price in short time to market forcing the foundry-suppliers to reduce the scrap with significant improvement on casting design and process optimization. The design phase assumes a significant role in this challenge in order to evaluate the possible product-process solutions to obtain the component with the maximum quality characteristics (0 defects, stress-strain reduction and nominal tolerances response).
The case presented, by Studio DSM, will show a design procedure that takes into account the design development from the filling phase to the problems related to the residual stresses and deformations typical of the HPDC process on a component developed for the consumer goods sector
My paper will be divided in two macro parts. First of all, a quick description of our company, since the foundation (1956) to the present. This part includes: our forming system (no-bake system) and a short view of which kind of pieces we produce. For the second part, the paper will analyze an effective business case, in particular we realized an engine stand, step by step, from the receiving of the 3D file for the maths from the customers, across the drawings of the casting system and addition of filters and sleeves, to arrive at the virtualizing of pouring and solidification. The last part of the paper will be formed by the conclusions. It will be studied the videos of pouring and solidification, to understand how the aluminium fill the shapes and the direction of solidification to the feeders. It will be concluded with a view of images that show the percentages of porosity and shrinkage, also a comparison between prototype before and later Magma.
HPDC process simulation using Magma 5 software integrated in the development of a new product and to improve parts already in production, software customization to make virtual reality closer to production reality
Bernardo Puddu, Brabant Alucast International
Brabant experience in the Magma 5 utilization in two main areas: new product development and solution of production issues.
In the first areas we set up a method that, used in an earlier stage of the project development, give opportunities to obtain an high level of optimization in terms of product and process design. This method makes really effective the process simulation.
In the production phase, process simulation can be an important tool to improve the casting quality. In this phase it’s particular important to co operate with the Production Department with a defined and clear protocol; the alignment with the real process is essential to create a strong instrument able to solve issues and improve casting quality.
Finally we show examples of our experience in customizing the method to tune the virtual environment with the production reality issue; we think this could be the way to evolve from standard users to become partner in software evolution, ready to be in line with the new challenges.
In this presentation, a complex industrial application of Magma simulation is discussed. Magma software is used to design modifications on die and corebox by Modelleria Brambilla. The possible occurrence of porosities inside the bosses in a large AlSi7 alloy cylinder block is studied. First, the problem is clarified by matching the preliminary simulations of the originally designed die and of the foundry adjusted one. The problem is critical since it is necessary to analyze the solidification dynamics even during the pouring phase. Then, two possible design solutions are modeled, simulated and then discussed with the foundry practitioners. Finally, a solution is codesigned with foundry technicians and engine designers. The final simulations of the modified die in different working conditions verify the robustness of the process. The modification has been implemented and the foundry equipment is currently operating with good quality results.
CAE software to optimize feeding system of butt-weldedvalves
Flavio Bettoni, Fonderia Augusta | Ernesto Imperio, CNR Istituto di Tecnologie Industriali e Automazione | Giampietro Scarpa, EnginSoft
In sand mold casting, one of the critical elements to have good results is the design of the feeding system, which must be optimized to increase the casting’s yield and the foundry’s process efficiency.
The paper describes activities and results within a traineeship at Politecnico di Milano in collaboration with Fonderia Augusta , Fluicon Valves and Enginsoft.
The case study consists in the design of a feeding system for butt-welded top entry valves for cryogenic service. Thanks to MAGMA 5, a CAE software provided by Enginsoft, the evaluation of different feeding systems and different casting’s positions in the mold has been possible.
At the same time the possibility to reduce valves thickness of non-standard parts has been evaluated.
The simulation of three different casting configurations has allowed to define the best solution characterized by 20% casting material reduction and a significant surface defects reduction.