Simulationsgestützte Optimierung der Maßhaltigkeit in der Prozesskette Druckguss (Volume 107) (English shop)

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Forward-looking vehicle concepts require progressive lightweight design in the vehicle structure in order to meet requirements regarding reduced fuel consumption and CO2 emissions. Thin-walled die-cast components serving as joining nodes are an essential element of weight-reduced vehicle bodies in multi-material design, yet owing to their large dimensions they exhibit process-induced deformations. In this work, simulation methods for predicting distortion along the die casting process chain are presented. For the simulation-based analysis of the die casting process with regard to the optimisation of these process-induced deformations, solutions for two different alloy specifications are demonstrated. For naturally ductile components without heat treatment, distortion can be compensated by allowing for the dimensional deviations in the die casting tool on the basis of process simulations. In contrast, for heat-treatable alloys the deformations occurring during the heat treatment process, in particular during solution annealing, are minimised by the simulation-based selection and design of the support of the castings. These methods are validated and optimised on the basis of two representative demonstrator components from the vehicle structure.