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﹁ In clear words
﹁ create a virtual model based on your reality,
﹁ experiment with this model
﹁ draw conclusions and gain knowledge for your reality
From „Simulation to Optimization“
Automatic Virtual Experiments
Initial State Optimization Best Compromize
Targets Process
variables /
Manual
Automatic
Degrees of Individual
Automatic
analysis and
freedom/ simulationof
simulation
evaluation ofof
assessment
Start ofvirtual
virtual
relevant quality
measurable
experiment
experiments
sequence criteria
quality criteria
Castable Design
Functional Desing
Producable Design
for HPDC
Functional Areas and Specifications
Specification of critical functional areas
Connection types
Self-piercing rivet
Monobolts
Flow drilling screws
Structural Adhesives
Final Design
lower
Risk of Coldflow
Filling Pattern
in upper Rip
smooth
higher
low high higher Material Quality of upper lower
Level of Porosity in lower Connection Point Connection Points
Simulation of residual stresses and distortion
Von Mises Stresses and Distortion Effective Plastic Strain resulting
after trimming from casting process
Optimum
Designs
Starting
design
Manually
optimized
v. Mises Stress
9.3s 14.3s 19.3s 24.3s 9.3s 14.3s 19.3s 24.3s
Visual Assessment of Experiments
Die Open
at 24.3s
Die Open
at 9.3s
Validation of FE-Crash-Analysis
Favourable
Critical area due Overlap ofhigh
to predicted
compression stresses
local loads from FEM Crash-
during crash Analysis
and residual High von Mises stresses form casting
– process with majorly tensile stresses
tensile stresses from
Increase risk of failure after ejection and cooling of casting
casting process
during crash
Why should I use virtual DoE’s?
Especially already during the early development phase
Your optimum
operating point
At the edge of
the process window
Instable Optimum
Process
Nominal Casting Design and Process Layout
Simulation model with Evaluation Areas of
several specified requirements
Typical shot profile for HPDC Castings based on
piston travel/velocity plot
Area 2
“Thin Wall” Deceleration of shot piston at end
of filling to avoid flashing
Area 1
“Connecting Points”
Spraying Conditions
Intensity of Spot Cooling
Intensification
Impact of Dosing Variation
Manageable Information – Main Effects
What happens with dosing variances ?
Start of Deceleration
“Breaking”
Start of Acceleration
“2nd Phase Velocity”
15 22,5 30
Minimal Dosing Nominal Dosing Maximal Dosing
–
31 corresponds to 25% variance on
total filltime of 30ms
27
15 (low) 22,5 (nominal) 30 (high)
Dosing
Expert Knowledge virtually generated
Correlation Matrix – Tendencies and Dependencies at a Glance
Area 2
Misrun Thin
Wall
Smooth Filling of
Runner/Gating
Smooth Filling of
Casting
Area 1 Porosity
Connecting Points
Max. Difference of
Filltime in Casting
Average Filltime
of Casting
Dosing
Variance
Analyze the Influence and Intensification
Depencies of all Process Variables Pressure
Quality Criteria
Wall
Smooth Filling of
Runner/Gating
Smooth Filling of
Casting
Area 1 Porosity
Connecting Points
Max. Difference of
Filltime in Casting
Average Filltime
of Casting
Process Variables
Space Frame
Heat treatment of a Structural Component
Version 02 Version 03
without large strut moved small strut
Identifying the best support frame layout
Initial Layout Verison 01 without small strut
Displacement Y
mm