Capabilities of new multi-objective Casting Process Optimisation tool

The aim of the Growth Project GRD2-2001-50042 “IDEAL” is the definition of integrated design methodology to optimise the cast aluminium components, in order to satisfy some societal needs: reduce car emissions of pollutants, improve safety and reliability of vehicles, and cut down requirements of raw aluminium. Four technological packages share theories and software development results in two horizontal main project outputs: a software tool that integrate methodologies to link design needs with process demands, and a software package for optimisation of casting processes. The numerical simulation can play a key role with respect to the design of a mechanical component as well as of the corresponding casting system. The objectives which drive the designer are generally well defined: improving the component quality, achieving homogeneous mechanical characteristics, maximising the die life, increasing the production rates, and the like. In reality it is very difficult to achieve all such objectives at the same time due to high number of variables involved. In the past, the only possible optimality approach was based on the experience, and hence on trial and error sequences from prototypes to a reasonable final design of the processes [1-5]. More recently, one result of IDEAL project is a novel optimisation technology that replaces the mentioned approach with much faster and low cost design and process methods, combining the foundry-man experience and the power of computer simulation [6]. A multi-objective optimisation can be performed by MAGMAfrontier that, sitting on the simulation codes, drive the virtual prototyping sequence to find the best compromise of optimal designs, taking into account various design and process variables and constraints, as well as different (and sometimes subjective and/or conflicting) technical, marketing and product metrics.