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Enhanced design and manufacturing of high resistance casted parts

Objective



The industrial objective of this project is to develop a new computational system tor enhanced design and production ot wide range of high strength casted components. The new computer based system will be based on improved existing computer methods for simulating the casting process integrating new material models, detect prediction models and fatigue life prediction models. The computer system will be validated by means of extensive experimental testing. The following tasks will form the core of the project activities: 1. Development of material models within a unified constitutive model framework and a database to characterise the casting process of carbon and stainless steel alloys, aluminium alloys and high strength cast irons. 2. Development of new defect prediction models and a database based on microstructure evolution and enhanced continuum constitutive relations. 3. Integration of material and defect models into existing numerical simulation codes for prediction ot residual stresses and defects at the end of the casting process. 4. Development and experimental validation of new fatigue life prediction models and database. 5. Integration and implementation of a computer based system for enhanced design high of strength castings. The system will be available at the end of the project for use within the partner's companies. 6. Industrial validation of the new computer based system on selected high strength casted components including an excavator tooth (steel alloy) manufactured by Partner 1, two aluminium alloy automotive parts (including one suspension arm) manufactured by Partners 2 and 4, a stainless steel valve for a food production machine and a SG cast iron component for a hydraulic pump manufactured by Partner 3. A schematic view of some of the components to be analysed is shown in Figure 1. 7. Proposal of a design support methodology combining the computer system to be developed in the project and experimental testing for fatigue life prediction of high strength castings. The purpose of the partners is to exploit both internally and externally the computer based technology developed in the project. The industrial partners related with the casting sector predict that the average design time of high strength casted components could be reduced in 30% and that the collectively could save 4 MEcu within three years of using the new fatigue life prediction system. A fully operational commercial fatigue lite prediction package is expected to be available after two years of completion of the project and will be marketed by Partner 5. Spin off applications of the research include fatigue lilfetime predictions of other metal products manutfactured via forging, extrusion, rolling, stamping and compaction procedures.

Coordinator

Metalogenia S.A.
Address
San Juan Bautista De La Salle
08330 Barcelona
Spain

Participants (10)

F Roda SA
Spain
Address

08510 Roda De Ter - Barcelona
FERESPE - FUNDICAO DE FERRO E ACO LDA
Portugal
Address
Brasiela-fradelos
4764-908 Famalicao
Fond-Stamp SpA
Italy
Address
Via Morozzo
12047 Rocca De Baldi
Fonderie 2A Srl
Italy
Address
Via Asti
10026 Santena - Torino
INSTITUTE OF MECHANICAL ENGINEERING AND INDUSTRIAL MANGEMENT
Portugal
Address
174-214,Rua Do Barroco 174/214
4465-591 Sao Mamede De Infesta
INTERNATIONAL CENTRE FOR NUMERICAL METHODS IN ENGINEERING
Spain
Address
S/n,gran Capitan S/n, Campus Norte Upc, Edificio C1
08034 Barcelona
LAEMPE GMBH
Germany
Address
Grienmatt 32
79650 Schopfheim
POLITECNICO DI TORINO
Italy
Address
Corso Duca Degli Abruzzi 24
Torino (Turin)
QUANTECH ATZ, S.A.
Spain
Address
S/n,calle Jordi Girona Salgado, S/n - Edificio Nexus
08034 Barcelona
Sonafi - Sociedade Nacional de Fundiçao Injectada S.A.
Portugal
Address
R. Santos Dias
4466 S.m. Infesta