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FP5

DILIGHT Résumé de rapport

Project ID: G5RD-CT-2000-00379
Financé au titre de: FP5-GROWTH
Pays: Italy

Software tool that permits to evaluate the effect of the manufacturing process on the real mechanical behaviour

The main objective of the DILIGHT research project was to develop a new generation of low cost high performance ductile cast iron for lightweight design of automotive components. In the framework of this project, the CRF has produced the following results.

- Economical evaluation:
In order to carry out a detailed cost analysis, the whole production chain has been considered and a software platform has been developed by CRF. In such a way it is possible to consider the effects of the modifications implemented in the process design phase (casting system geometry and process parameters) not only as far as the casting phase itself is concerned, but also all the other centres that allow the product manufacturing.

Moreover, this methodology permitted not only to quantify the entire sand casting manufacturing cost, but also even to accurately monitor each constituent cost item. Indeed, the whole computed cost has been split into single components in terms of material, energy, labour, equipments, premises, maintenance, consumables and machinery set-up. It is worth noting that the performed cost analysis, and therefore the following considerations, have been based on a particular chosen manufacturing process, characterized, for instance, by a certain distribution of the depreciations and maintenance costs and by real production capacities and business volumes.

- Software tool that permits to evaluate the effect of the manufacturing process on the real mechanical behaviour:

In order to transfer the information deriving from the simulation to the microstructure modelling, it was developed a dedicated software tool. The considered step are: remeshing, displacement transfer, stresses transfer, input file compilation.

Furthermore, this methodology permit to evaluate the effect of the manufacturing process on the real mechanical behaviour of the component. The obtained results clearly demonstrate the influence of the preexistent stresses.

Contact

Silvio ANTONIONI, (Project Manager)
Tél.: +39-046-1412314
E-mail