Work Package 1: Horizontal integration of process simulation into the design chain.
Within this Work Pack a new methodology will be developed for the horizontal integration of design between structural FEA simulation and process simulation. Material characteristics will be taken into account. The following main topics have to be addressed:
1. Robust links between matrices being used in process simulation and the Finite Element matrices used in FEA to be created.
2. The conversion of result files from the process analysis of residual stresses to be exported as input parameters for FEA.
3. The conversion of casting properties that result from process analysis to be exported into FEA as property fields.
4. The integration of software developments and tools of the other
Work Package 2: Microstructure and property micromodelling.
Based on micro structural modelling approaches, a comprehensive simulation tool will be developed for castings of industrial interest (or with geometrical features that represent an industrial component). Quality and property determining aspects will be taken into account.
Work Package 3: Quality mapping.
The main objective of this Work Pack is to study the filling behaviour of a molten metal inside some significant kind of die cavities, to identify more suitable parameters, and from a general point of view, to describe of the origin of any defects. Some correlation between the defects classified and studied on the basis of industrial case histories will be defined. more suitable more suitable The rules pertaining to the simulation code will be implemented and a database of the typical features of any defects will be set up. The results will be used to define guidelines for the upgrade of EN standards, in terms of alloy mechanical properties.
Work Package 4: Stress analysis.
The main objective of this Work Pack is to calculate and reproduce residual stresses during the casting process, from cooling down to room temperature and the following heat treatment in order to:
- Develop a methodology for stress calculation in castings
Work Package 5: Post-Casting treatments.
The main objectives of this Work Pack are:
- To set up an industrially significant LHIP (Liquid Hipping Process), to be applied to Aluminium castings and to be modelled into process simulation codes.
- To review the effects of conventional heat treatments on microstructure and on properties, and to evaluate such effects into process simulation codes.
Work Package 6: Process optimisation.
The objectives of this Work Pack are:
- To provide optimisation tools which integrate with process simulation software.
- To assess the results that can be obtained by using process optimisation through user test cases.
The activity is correlated to the development of process optimisation. This Work Pack will benefit from the results of the other WPs, where the simulation capabilities are developed on the basis of experimental activity.
The optimisation tool will be tested by means of demonstrator components produced inside WP7.
Work Package 7: Component integration- Automotive industry.
The various tools and integrated methodology developed in the framework of the IDEAL project (from gravity and die-casting processes) will be validated on chosen components. Simulations of processes and of structural analysis will be undertaken with experimental phases in order to verify the methodology.
Work Package 8: Project Management.
The project management procedures are described in full detail in section 5.2. The project co-ordinator will be responsible for the administrative and technical co-ordination of the project as detailed in the table for Work Package 8. A project co-ordination committee comprised of one senior member from each organisation will meet every 6 months on a regular basis ( 1, 6, 12, 18, 24, 30, 36) to assess the project, discuss and agree on the different phases of the project and revise work programmes as necessary. Additional interim meetings will be arranged as required.
Work Package 9: Exploitation of results.
The main results will be monitored through the organisation of dedicated seminars open to participants not in the consortium. Exploitation and dissemination activities are distributed throughout the whole period of the project. All partners will contribute to the assessment of internal exploitation of the project through periodic critical evaluation of the results obtained. All aspects concerning the utilization of project results will be evaluated in view of an industrially relevant use of the integrated software tool developed.