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Scientists and researchers have the opportunity here to present and share their work with the community and build up their network. Companies can also present their technical developments and concepts.

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Audio Signal Processing for Quantitative Moulding Material Regeneration

Philine Kerst, M.Sc.

University Duisburg-Essen

As a natural product with limited resources, sand is of existential importance for various industries. Foundry technology in particular requires considerable quantities worldwide for sand moulds and cores. Depending on the process, the sand is recycled and thus reused. However, especially in the case of inorganically bound moulding sand, it is still frequently not recycled. Existing regeneration methods include mechanical, pneumatic, or combined processes. These have been developed, but have reached their analytical optimisation limits, as the processes are not transparent and make in situ analyses of moulding materials impossible. Within the scope of this research work, a methodology for the computer-aided processing of sound and image data with the help of convolutional neural networks (CNNs) was developed, which is to evaluate the non-measurable changes of the moulding material in the running process in real time via process acoustics. The aim is to optimise process control in terms of time, cost, and energy efficiency.

Keywords: Regeneration, Audio Signal Processing, Machine Learning

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The Future of Structural Components in HPDC

Dipl.-Ing. (FH) Hermann Jacob Roos

Bühler AG

The market for structural components has multiplied over the past years and expanded with battery housings, especially driven by the electrification of the drive train, and most recently megacasting applications.
In order to make structural parts even more attractive especially for high volume vehicle segments cost savings for this application are crucial. Cooperation across the industry is essential for further development of structural processes that will enable large series production. The presentation highlights the potential cost savings by increasing productivity through thermal management, by the selection of alloys and avoiding thermal heat treatment and by enabling lightweight design of the structural parts.

Keywords: Megacastings, Structural Components, HPDC

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Hot distortion of bonded sand cores – Core deformation during filling

Jesper Thorburg, Associate Professor

MAGMA GmbH

Dimensional tolerances in castings, especially for filigree shapes, are very dependent on the distortion of the sand cores used to form the casting contour during the casting process. Despite its importance for casting and component quality, up to now very little effort has been expended to truly understand the behavior of these cores during casting. This situation is changing, especially due to the increasing interest in inorganic binders and the corresponding process changes resulting from a change in binder systems. This work shows the approach to determine the Hot distortion of bonded sand cores during filling.

Keywords: Core deformation, Stress, Sand Cores

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COMING SOON: How Sand 3D printing is reviving small and medium size foundries

Necip Cirakman

ExOne GmbH

Binder jet 3D printing is revolutionizing sand casting – capable of producing complex cores that cannot be produced in any other way – and organic rigging designs that help to make successful precision pours and decrease scrap rates significantly. Foundries embracing the digital workflow are expanding business by offering rapid prototyping with easy design iterations, fast turnarounds without lead times. Technological advances in robotics are making 3D printing more accessible than ever and the all-new S-Max Flex binder jetting system was developed to help smaller foundry businesses survive and thrive. In this conference talk we’ll explore the economics of integrating a digital workflow with 3D printing to help get products to market faster, made regionally. Participants will learn how sand 3D printing fits in their foundry and they’ll be introduced to the S-Max Flex robotic 3D printing process that delivers quality parts from an affordable, easy-to-use system.

Keywords: Binder Jetting, Robotic 3D Printing, 3D Core Making

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Role of simulation in the Digital Die Casting Cell

Beat Eberle, M.Sc.

Bühler AG

Nowadays the development of new Die Casting machines would be hardly possibly without using simulations because of the size of the components e.g. platens with a weight of 100 tons and rough dimensions of about 5m x 5m x 3m. In this range there is no possibility to create a physical prototype. So it must be done in the first time right. This talk will show the importance of combining modeling and simulation tools for the devevopment of new Die Casting machines as well as how this can be integrated in the so called Digital Die Casting Cell.

Keywords: Die Casting, Simulation, Digital Twin