Implementation of Casting Process Simulation for Increased Engine Performance and Reduced Development Time and Costs – Selected Examples from FORD R&D Engine Projects

Authors

Prof. Dr.-Ing. Dr.h.c. R. J. Menne, Dr.-Ing. U. Weiss, Ford Research Centre, Aachen; Dr.-Ing. A. Brohmer, FordWerke GmbH, Cologne; Dr.-Ing. A. Egner-Walter, Dipl.-Ing. M. Weber, P. Oelling, MAGMA GmbH, Aachen

Year

2007

Print Info

Fortschritt-Berichte VDI, Reihe 12, Nr. 639

Summary

The application of CAE is continually gaining importance in all areas of engine development. This is especially true for the simulation of the casting process as well as for the following heat treatment. Although the durability analysis of the finished component has long been an established part of the development process, only recently CAEtechnologies for the simulation of the manufacturing process have come into focus. The advantages of simulation at an early stage are obvious. Only by using the simulation of the manufacturing process it is possible to determine the distribution of inhomogeneous mechanical properties (hardness, elongation and yield strength) as well as residual stresses and to consider these properties in the design optimization process, especially in FEM calculations.

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