Simulation for process design and optimization of aluminum cylinder heads

The Daimler-Benz foundries have the responsibility to deliver several cylinder heads for Mel cedes-Benz cars. To meet the challenging schedules Sor new casting and die designs, the application of simulation tools for die design and process optimization has become art integral part of the workflow. Hence, the Daimler-Benz foundries do not only perform the die design and manufacture of permanent molds, but also have invested substantial effort in validating different manufacturing routes within, and an alternative to the conventional permanent mold process. Simulation tools have been applied to verify the different design alternatives. The value of such a procedure is demonstrated in various cases, and proves the potential of simulation tools to support the status of the foundry as an active partner within the design chain of a large automotive company.