Förbättring av design för gjutning av lyftöron till pressverktyg

Abstract

This bachelor thesis was done in collaboration with Volvo Cars in Olofström and is about improving the castability of the lifting lugs on their stamping tools. The project started when they, by a coincidence, discovered a cavity behind one of the lifting lugs. This led to the question of whether it could occur in more lifting lugs since it is standardized, and what could be done to prevent it from occurring. The goal of the project is to propose ideas on how to change the geometry to improve the casting quality of the lifting lugs. The report covers FEM-modeling and strengthening calculations in CATIA v5 of various geometry changes, where the starting point for the changes comes from literature as well as data from casting simulations provided by the foundry Massifond. The work examines what geometry changes that can be implemented to counteract defects that can occur during casting of the lifting lugs to the stamping tools. The occurrence of various defects is investigated, but the defect the reports deals with in particular is the cavity found in the casting. First, a literature study and reading on the subject was conducted to gain an understanding of the problem. An investigation of the problem was also done by discussing with the designers at Volvo Cars and the supervisor at Chalmers. The conclusion of the report is that there are great opportunities to reduce the mass and change the geometry without the strength deteriorating and becoming worse than the original construction.