Also for magnesium, the changes in the properties of a cast body as the result of subsequent forming were investigated. 2 They investigate the application of cast aluminum alloys by use of combined software for the prediction of component properties and comparison with wrought alloys.

Zhenglong and Qi show a combined process of squeeze casting and forging for improving the quality of control arms. 1, 2 Perrier et al describe a process flow, based on a casting/forging process (Cobapress ™) for the weight reduction in aluminum alloy wheels 1 without considering the simulations or their linking. In the field of non-ferrous metals, preferably aluminum and its alloys, the processes are already closely linked for the production of automotive components. It is the very aim of the present paper to meet this demand by linking and evaluating the simulations of both process types. In order to achieve these advantages the combination of both disciplines would be necessary at the product development phase. Furthermore, the forging process can be used to minimize or eliminate defects resulting from the casting process such as blowholes or pores. Simultaneously, a reduction of material usage and a shortening of production steps becomes possible by this process combination. The approach combines the main advantage of casting, that is, complex geometry generation, with the best of forging, that is, high strength and robust mechanical properties. The combination of casting and forging is an innovative manufacturing method to bring together the best from both well-established technologies. Approaches for further investigations and the improvement of the combined simulation are presented. In addition, the microstructure of the components was investigated.

The simulation results, especially voids and porosity were compared with the real components. Based on the conditions assumed in the simulations, test components were manufactured. To predict the expected properties, the necessary simulations were linked, whereby the focus of the investigations is on the principle feasibility and methodology of such a combination. The present paper describes a forged steel component based on a cast preform. In the manufacturing of steel components, such a combination is not known industrially. However, with the development of digital technologies, it has recently become possible to jointly simulate casting and forging processes and set up continuous process simulations. In the past, the processes usually were considered separately. In the aluminum sector as well as in the manufacture of semi-finished products, there are numerous industrial examples for combinations of casting and forming processes.

Casting simulation software open source