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Technical University of Munich
Technical University of Munich

Efficient development of thin-walled die-cast aluminum components by avoidance of casting production obstacles

In order to provide a casting system for pressure die-casting components, the possibilities of process simulations are already being used intensively. However, the construction process is mainly based on experience and therefore not solid. Furthermore, the construction becomes more complicated due to unknown casting barriers. Systematization of the product development process of pressure die-cast components, both in the construction area as well as in the decision-making of the means of production, is the target of this research project. That way, not only avoidable simulations can be limited, but also the shortening of development time is possible.

Unlike other already existing approaches, it is not about analyzing present constructions, but supporting the engineer in order for him to be able to identify casting problems early enough to avoid them. In the context of this research project, obstacles which could occur during the filling of a pressure die-cast mold are being looked at. A proposal for a casting system will be provided, as a result of the developed methods during this research. Component characteristics will be analyzed and evaluated locally. Obstacles, which occur during production, will be reported to the user and the casting system will be adjusted automatically. As a result, the engineer receives information regarding the manufacturing process as well as the feasibility in time. The person responsible for the casting system will be supported by a systematic approach, especially regarding complex component structure.