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TOLLENAERE INPG, G-SCOP Laboratory, Grenoble, France andĪ C.I.P. TICHKIEWITCH INPG, G-SCOP Laboratory, Grenoble, France Two keynote papers, one presented by Professor Stephen Lu, from the IMPACT Research Laboratory, University of Southern California, USA, on Supporting participative joint decisions in integrated design and manufacturing teams, and one written by Professor Stefan Rudolph from Stuttgart University about Know-How Reuse in the conceptual design phase of complex engineering products or: Are you still constructing manually or do you generate already automatically, introduce the subject of the Conference and are followed by the different themes highlighted during the conference: The design/manufacturing interface Integrated design of manufacturing processes Life cycle design and manufacturing approaches Agility in design and manufacture Knowledge in engineering and Management in production systems.ĪDVANCES IN INTEGRATED DESIGN AND MANUFACTURING IN MECHANICAL ENGINEERING IIĪdvances in Integrated Design and Manufacturing in Mechanical Engineering II Edited by The parallel coordinates diagram allowed to easily identify the parameters that characterized the best process conditions and runner design fulfilling the required quality (Figure 3).The 33 papers presented in this book were selected from amongst the 97 papers presented during the sixth edition of the International Conference on Integrated Design and Manufacturing in Mechanical Engineering during 28 sessions. The MAGMASOFT ® scatter chart showing the two main objectives (amount of air entrapment and surface turbulence during filling) allowed identification of the best design (one dot represents the results of one virtual experiment). To get a sound understanding, 192 different designs were analyzed constituting the basis to choose the best solution.
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The target was to minimize air entrapment, surface turbulence and shrinkage porosity as a function of different process variables and modifications in the runner and gating design. Applying the MAGMA APPROACH, they started by deciding on the objectives to be reached. To establish robust process conditions, the Tecnopress designers used the virtual optimization capabilities of MAGMASOFT ®. A close investigation of the results of the virtual analysis confirmed air entrapment to be the main cause of the defects, which was related to the specific filling dynamics. Two areas of the casting characterized by concentrated porosity were close to machined surfaces, resulting in the high scrap rate.
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The assessment also highlighted some concerns, especially regarding air entrapment in some areas of the casting (Figure 1). It is therefore subject to strict quality tests carried out in every production phase, from casting to final assembly.Ī first analysis confirmed the design considerations of the Tecnopress engineers regarding velocity and temperature distribution during filling. The component is not subject to heavy mechanical loads, but has to have perfect pressure tightness with high reliability. One automotive casting designed by the Italian engineers is a cover for a pneumatic valve in a braking system, mainly used in heavy duty machines. This allowed the company to reach required quality levels without affecting production costs. Tecnopress S.p.A., Italy, has applied the methodology of virtual experimentation with MAGMASOFT ® to enhance production processes of automotive components for many years. This ideally takes place simultaneously with the tool design during the planning phase. Therefore, establishing a robust process design is crucial in order to establish an optimized process window. This can lead to air entrapment or incompletely filled parts. One of the key drawbacks of the process is the inherent high metal flow velocity resulting in an extremely turbulent filling behavior. This casting process offers a competitive manufacturing route for mass production, as a high productivity goes together with high precision components.
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Die-casting is one of the key processes for the production of automotive components.