Process Optimization for Additive Manufacturing in the CustoMat 3D ProjectĪdditive manufacturing processes are catalysts for technological innovations. “Smart Control and Cognitive System applied to the HPDC Foundry 4.0”Įdited by Nicola Gramegna and Franco Bonollo, Assomet Servizi Srl, Enginsoft SpA In addition a booklet is available, which summarizes the main results of the project: More information can be found on the project website: At the end, also real demonstrator components like a shock tower from the partner Audi were used to apply the generated know-how.įor such a Meta-model to be realized, numerous experimental data were generated, and MAGMA additionally added virtual experiments (DoE), with varying process parameters and their influence on the casting quality, to train the Meta-model before foundry trials started. New criteria for the simulation were developed and validated with the help of a “horse shoe” test geometry. One objective of MAGMA in the project was to improve the quality prediction of the high pressure die castings with simulation.
The idea behind the project was to link the new Control and Cognitive system to real-time monitoring for an active quality control. This ambitious and challenging goal can support High Pressure Die Casting and Plastic Injection Molding Companies in achieving lower scrap generation, higher efficiency and robustness, and minimize energy consumption. The Music Project was aimed at developing a “ MUlti-layers control & cognitive System to drive metal and plastic production line for Injected Components“ under the EU Factory of the Future initiative, targeted at improving efficiency, adaptability and sustainability of manufacturing systems as well as their better integration within business processes in an increasingly globalized industrial context. Ī detailed project summary can be found here: Bundesministerium für Bildung und Forschung. Project partners in this project were Audi AG, Eisenwerk Brühl GmbH, Meuselwitz Guss GmbH and Walter Hundhausen GmbH, Fraunhofer Institute for Operational Strength and System Reliability LBF, Fraunhofer Institute for Technological and Economic Mathematics ITWM, Germanischer Lloyd Industrial Services GmbH, Institute of Foundry Technology IFG and MAGMA Gießereitechnologie GmbH. The project was carried out as a joint project between and.
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This research and development project was funded by the Federal Ministry of Education and Research (BMBF) under the funding code 01RI0713 and was supervised by the German Aerospace Center (DLR) in Bonn.
This makes it possible to calculate the expected durability for the materials GJS-400 and GJV-450 based on a casting simulation and to transfer this information as input for durability calculations. In addition, the necessary interfaces for data exchange with programs for fatigue life calculation (for example, FEMFAT, LMS Virtual Lab Durability) were created. A correlation between the local durability and the local microstructure was determined. For this purpose, MAGMA developed a calculation procedure in which process simulation was integrated into computational fatigue calculations. Within the scope of the MaBIFF project, the prediction of local microstructures was extended.
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