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Hot distortion of bonded sand core 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

Hot distortion of bonded sand cores – Core deformation during filling Jesper Thorburg, Associate Professor MAGMA GmbH contact me via LinkedIn 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

Hot distortion of bonded sand cores – Core deformation during filling Jesper Thorburg, Associate Professor MAGMA GmbH contact me via LinkedIn 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

Audio Signal Processing for Quantitative Moulding Material Regeneration 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

The Future of Structural Components in HPDC Dipl.-Ing. (FH) Hermann Jacob Roos 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

The Future of Structural Components in HPDC Dipl.-Ing. (FH) Hermann Jacob Roos Bühler AG contact me via LinkedIn 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

The Future of Structural Components in HPDC Dipl.-Ing. (FH) Hermann Jacob Roos Bühler AG contact me via LinkedIn 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

Role of simulation in the Digital Die Casting Cell Beat Eberle, M.Sc.

Audio Signal Processing for Quantitative Moulding Material Regeneration Philine Kerst, M.Sc. University Duisburg-Essen contact me via LinkedIn 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

Audio Signal Processing for Quantitative Moulding Material Regeneration Philine Kerst, M.Sc. University Duisburg-Essen contact me via LinkedIn 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

Role of simulation in the Digital Die Casting Cell 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

Role of simulation in the Digital Die Casting Cell Beat Eberle, M.Sc. 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