Optimizing of AlSi10Mg alloy casting production using numerical simulation

Abstract

Razvojni ciklus proizvoda, u današnje vrijeme, zahtijeva izvrsnost rezultata od prvih komada, ekonomičnost, pouzdanost i kratke vremenske rokove s ciljem očuvanja konkurentnosti na globalnom tržištu. Greške koje dovode do gubitka vremena, novca i zastoja u proizvodnji su potpuno preventabilne korištenjem suvremenih koncepcija optimiranja procesa lijevanja baziranim na virtualnim rješenjima numeričkih simulacija i današnje računalne tehnologije. Simulacija je virtualni proces koji prikazuje realni proces lijevanja u svrhu njegovog razumijevanja i preventivnog uklanjanja neželjenih grešaka u postupku razvoja proizvoda od konstrukcije proizvoda, alata do samog postupka lijevanja konačnog proizvoda. U ovom radu provedeno je optimiranje proizvodnje odljevka od AlSi10Mg legure uz prikaz svih koraka. Uočeno je visoko podudaranje procesa proizvodnje s virtualno simuliranim procesom. Proizvedeni odljevak je ispravan, bez ljevačkih grešaka i neplaniranih dorada. Razvojni ciklus proizvoda je značajno kraći u odnosu na klasični razvoj bez primjene numeričke simulacije proizvoda i tehnologije proizvodnje.The product development cycle, nowadays, requires excellent results from the first pieces, economy, reliability and short deadlines with the aim of maintaining competitiveness on the global market. Defects that lead to loss of time, money and production stoppages are completely preventable by using modern concepts of optimizing the casting process based on virtual solutions of numerical simulations and today's computer technology. Simulation is a virtual process that shows the real casting process for the purpose of understanding it and preventively removing unwanted defects in the product development process from product construction, tools to the final product casting process itself. In this paper, the optimization of the production of castings from AlSi10Mg alloy was carried out with a presentation of all steps. A high match of the production process with the virtually simulated process was observed. The produced casting is correct, without casting defects and unplanned additional finishing. The product development cycle is significantly shorter compared to the classical development without the application of numerical simulation of products and production technology