Vehicle light weighting using a new CAE tool for predicting thin film defects in high strength castings

This paper will discuss some of the challenges of creating light weight body structures in the highly competitive luxury automotive sector, where cast components can account for over 10% of the total vehicle mass. In particular a new method for predicting the defects introduced in castings during manufacturing will be discussed. Whilst cost and weight benefits are already being realised through the use of castings, significant opportunities for weight reduction remain. Advanced CAE techniques have the potential to play a major role in the optimisation of castings, but it is essential that accurate material properties are used in any analysis. These properties need to include local defects or variations in properties that are introduced during the manufacturing process and this paper will discuss a new technique to predict thin film defects in both high pressure and gravity die castings. The work discussed in this paper has been conducted through a collaboration of industrial and academic partners, funded by the TSB under the 'High Value Manufacturing' work stream.