Mid term report for IDEAL project

The main objective of this report is to describe the progresses in the WP4 achived at the mid term of the IDEAL project. The main objective of work package 4 is threefold: Firstly, obtaining a reliable forecast of the residual stresses and strains directly from the casting simulation. For this purpose the process simulation must include a thorough thermomechanical analysis itself.

This is already possible in the FV-based process optimisation tool MAGMAsoft, although it is further being developed in the work package with respect to the constitutive description of the aluminium parts at high temperatures. Secondly, establishing a reliable model for the thermomechanical conditions during the subsequent heat treatment of the cast aluminium parts.

In this process, several approaches involving both simple visco-plastic models as well as more complex unified models are taken. Thirdly, coupling of the casting simulation, the heat treatment simulation as well as a possible subsequent load analysis together and thereby addressing the entire CAE-chain.