Simulation of Casting Processes

The importance of modelling and simulation in production technology is increasing due to the steady shorting of development times. This is motivated by the optimisation of the production processes, the enhancement of product quality and a reduction of costs. The application of numerical modelling is especially recommended in the development of new production methods and in use of new materials.

Modelling and simulation at the Neue Materialien Fürth GmbH (NMF) focuses on casting technology. The most important questions that can be solved by means of numerical methods are the optimisation of the casting process as well as the design of the part and the mould. For a given shape of a part, the ideal gating and venting system is designed in shorter time on the basis of fluid dynamical calculations. Part quality and part properties are derived from solidification analysis and the prediction of casting defects. The description of stresses and part distortion is useful in the adjacent machining process as to assure shape.

Recent investigations at NMF focus on high pressure die casting of aluminium and magnesium alloys as well as thixomolding of magnesium alloys. In terms of the design the focus is on thin walled light weight components for the automotive industry.

The equipment of the Neue Materialien Fürth GmbH contains all necessary tools to work on real, full 3D moulds and castings, like commercial CFD codes dedicated to casting technology, post processing tools for proper interpretation of the results, thermodynamical databases to determine solidification and an advanced CAD environment, including data conversion.

Filling simulation of the high pressure die casting process

Comparison of the simulation results and filling experiments
left: filling experiment - approximitly 25%
right: simulation results