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from five different road conditions was developed and imported into nCode DesignLife. Stresses computed by Altair OptiStruct from unit loads also were in- cluded, enabling the engineers to assemble stress his- tories for all locations on the wheel carrier. This data, along with material properties from the DesignLife’s database, was used to predict fatigue damage. Click2Cast (C2C) casting simulation was used at


two points—the beginning and end—in the design process. In the early phase, C2C allowed designers to test the manufacturability of the component design and optimize it, avoiding internal defects and analyz- ing critical areas while also reducing iterations be- tween the design and production departments. At the end of the design phase, C2C was used to simulate the full mold filling process and thermal solidifica- tion, helping create the most efficient manufacturing method and minimizing any waste in energy, time, and materials. With optimization, fatigue analysis, and casting


simulation complete, the results were sent to voxeljet to 3-D print the molds. Using CAD data, voxeljet produces plastic models by applying a particulate material (in this case, polymethylmethacrylate, or PMMA) in layers, bonded with a binding agent. This organic material results in a very low ash content and zero pattern expansion, with perfect burn-out characteristics, and is therefore well suited for invest- ment casting. With excellent dimensional accuracy and high-quality surface finish, PMMA 3-D printed models allow for highly complex designs that are me- chanically stronger than previous cast designs. While cast designs may be lighter in weight, the 3-D printed plastic models cost vastly less to produce, having no tooling investment. “We are very pleased to realize such an innovative


initiative with our partners,” said Mirko Bromberger, marketing director, Altair Engineering GmbH. “The technology demonstration clearly shows the potential this integrated process offers. By combining optimi- zation, fatigue analysis, casting simulation and 3-D printing, it is possible to leverage the full potential of lightweight design or, as in this case, significantly improve performance without compromising weight goals. With this wheel carrier component, Altair, our APA partners Click2Cast and nCode, and voxeljet have proven that a paradigm change in how products are developed is possible and already available today.” The entire process, including the 3D printed molds and the final cast aluminum component, will be displayed at at the GIFA 2015 in Hall 13 Stand B34. 


DesignLife中。其中还包括了Altair OptiStruct计 算得出的单元负载应力,使工程师可以搜集轮架上 所有部位的应力数据。这些数据与DesignLife数 据库中的材料性能用来预测疲劳损伤。Click2Cast (C2C)铸造模拟软件用于两个点——设计过程的开 始和最后。早期阶段,C2C公司有助于设计师测试 铸件设计的工艺性并对其优化,避免内部缺陷并分 析关键部位,同时还减少设计和生产工部的重复工 作。在设计的最后阶段,C2C用于模拟完整的充型 过程和热凝固,从而有助于产生最有效率的生产方 法,并将能源、时间和材料的消耗降到最低。 通过优化、疲劳分析和铸造模拟完成以后,其结 果发送到voxeljet公司进行3D打印铸型。voxeljet 公司利用CAD数据、使用微粒材料(在此使用的是 聚甲基丙烯酸甲酯,或PMMA)生产由粘结剂粘结 的分层塑料模型。这种有机材料的灰分含量很低、 模型的膨胀为零,并具有完美的燃尽特性,因此, 更适用于精密铸件。PMMA的3D打印的模样具有 优秀的尺寸精度和高质量的表面光洁度,使其适用 于机械强度高于原先铸件设计的非常复杂的设计。 然而,铸件的重量将更轻,3D打印的塑料模样的生 产成本更低,而且没有模具方面的投资。 “能够与合作伙伴取得如此具有创新性的成果, 我们为此感到非常高兴,”Altair工程公司市场总 监Mirko Bromberger说:“该项技术明确展示了 工艺整合后所具备的潜力。通过把优化、疲劳分 析、铸造模拟和3D打印结合在一起,就有可能充 分挖掘出轻质设计的潜力,比如在这个例子中,在 不需对产品重量做出让步的同时显著提高了性能。 通过该轮架铸件,Altair公司、我们的汽车铸件合 作伙伴Click2Cast(两点铸造)公司、nCode(恩 科)公司和voxeljet公司已经证明,产品研发中的 范式改变是可能的,而且目前已经具有可用性。” 整个工艺过程,包括3D打印铸型和最终铝合金 铸件,将在2015年汉诺威展览会的7号馆展出。 


June 2015 FOUNDRY-PLANET.COM | MODERN CASTING | CHINA FOUNDRY ASSOCIATION | 85


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