Integrated approach to component design for automotive applications

Abstract

An integrated approach to design considers every aspect of the life cycle of a component during the design stage. Starting from the initial concept till the component dismission, a lot of variables are taken into account in order to develop a component with improved quality and well-known potentiality, reducing at the same time cost and time to market. Today, these requirements are duty for automotive companies as a consequence of an increasing competitiveness and a complex market. In order to achieve this objective, numerical simulation process plays a key role because it allows to predict the evolution of a component during both designing and working life since the product concept. The possibility to forecast defects, microstructure and mechanical properties of castings reduces costs and efforts, improving quality and reliability at the same time. In this work, a new methodology was applied for the development of an A356 aluminium alloy monocylinder, cast by means of Low Pressure Die Casting. Casting simulation, in terms of solidification time, defects and die temperature, is proposed along with microstructural features and mechanical properties, virtually predicted in as-cast and heat treated temper. Furthermore, a comparison of experimental data and numerical simulation results was performed and discussed