integrated design procedures for volume produced cast aluminium automotive components
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8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Integrated Design
Procedures forVolume Produced
Cast Aluminium
Automotive Components
Jonathan James John Spittle
Steve Brown Ian Pearce
Tony Firkin Janardan Devlukia
Presentd by Dr. Zongjin Lu, Land Rover
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Cast Aluminium Components• Automotive Weight Saving
• Need To:
– Minimise Casting Defects
– Achieve Acceptable Properties
• Design Dilemma - Thicker Gauge Sections Give:
– Lower Stresses – Slower Cooling
– Poorer Materials Properties
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Aluminium alloy LM25 (A356.0) : Al 7Si Mg
0
50
100
150
200
250
300
0 10 20 30 40 50 60 70
Dendrite Arm Spacing, microns
S t r e n
g t h , M P a
0
2
4
6
8
10
12
D u c
t i l i t y , %Strength
Ductilty
Source : A.Wickberg et al, SAE Technical Paper Series 840121,
Mechanical Properties depend on:
• Chemical composition – Si, Mg, Fe, H
• Grain refinement
• Cooling rate during solidification
• Porosity levels
• Heat treatment
Strength
Ductility
DAS
- Al
Si
FeSiAl5
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Objectives
• Integrate
– Component Design
– Casting Design
• Combine expertise from: – Car Manufacturers
– Foundries
– Suppliers of Casting Simulation Software
• Re-Design a Prototype Component
• Develop New Design Procedures
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F A S T M A T
University of Warwick - Nov 4, 2003
Software Used• Computer Aided Design
• FEM Mesh Generation
• FEM Stress Analysis
• Solidification Simulation:
– Fluid Flow – Liquid Metal Mould Filling
– 3D Finite Difference Solidification Simulation – Prediction of Freezing Times + Porosity
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F A S T M A T
University of Warwick - Nov 4, 2003
Methodology
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Prototype Component
Rubber
Bush
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F A S T M A T
University of Warwick - Nov 4, 2003
View of component on car
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F A S T M A T
University of Warwick - Nov 4, 2003
Summary of Designs
89889278100Component
Weight
75757575100Section
Thickness
282127137100100Section
Area
11 12 13 14Original
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F A S T M A T
University of Warwick - Nov 4, 2003
Original v New Designs
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Original ComponentFeeders
Runner
Filter
Sprue
Main Ring
Bosses
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F A S T M A T
University of Warwick - Nov 4, 2003
Final
Filter
Runner
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150
MPa
0
75
Von Mises Stress
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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300
Sec
120
210
Local Freezing Time
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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75
m
50
63
Dendrite Arm Spacing
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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180
MPa
100
140
Nominal Yield Strength
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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40
GPa s
0
20
Max Prin Stress x
Loc Freezing Time
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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1.0
0
0.5
Von Mises Stress /
Nom Yield Strength
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Max Values From Mesh
MP / Nom Tensile Strength
VM / Nom Yield Strength
MP x LFT
MP x T80
VM x LFT
VM x T80
Max Principal Stress
Von Mises Stress
0.791.03
0.770.96
31.942.0GPa s
40.346.7GPa s
31.439.4GPa s
39.543.8GPa s
138187MPa
120170MPa
NewOriginal
8/3/2019 Integrated Design Procedures for Volume Produced Cast Aluminium Automotive Components
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F A S T M A T
University of Warwick - Nov 4, 2003
Original New
Original New
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F A S T M A T
University of Warwick - Nov 4, 2003
Strength
Testing
54.5940.33Mean
61.8439.5742.4439.14
58.1141.48
55.9641.12
NewOriginalkN
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F A S T M A T
University of Warwick - Nov 4, 2003
Fatigue Test Results
25
24
21
27
20
20
20
2326
22
0
5
10
15
20
25
1.E+05 1.E+06 1.E+07 1.E+08
Cycles to Failure
L o a d ,
k N
Original Design
New Design
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F A S T M A T
University of Warwick - Nov 4, 2003
Summary
• Developed design procedures thatcombine:
– FEM in-service stress analysis
– Computer model of solidification process
• Prototype Component:
– 36 % increase in strength
– Substantial Increase in Fatigue Life
– 5 % Weight Reduction
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F A S T M A T
University of Warwick - Nov 4, 2003
Future Work
• Possibly Extend Casting Simulation to Include:
– Stress Analysis as Casting Cools
– Residual Stress Determination
• Need Mechanical Property Data for:
– Semi-solid condition
– and just below solidus