Smart casting processes

– establishing digital twins based on advanced sensors and models

3 May 2021
Online via MS Teams

This seminar describes the framework of smart casting processes, where sensors are built into the moulds making it possible to monitor critical process parameters such as temperatures, temperature gradients etc.

This data, in combination with advanced multi-physics mathematical models, forms the basis of complex decisions regarding process setup and execution. The ultimate goal is to improve part accuracy both in terms of geometry and dimension, and also in terms of material properties. This is important for all sizes of cast components, and the seminar will show industrial examples of the need of this approach.

09:00 - 09:05
Welcome by Hans Nørgaard Hansen, Professor & Head of Department, DTU Mechanical Engineering
09:05 - 09:40
Digital twins and modelling in manufacturing processes

Jesper Hattel, Professor, DTU Mechanical Engineering

The ongoing digitalization is transforming industry in a disruptive manner and production of products is no exception. Here, digital twins are increasingly used to analyze and optimize manufacturing processes based on a combination of measurements and mathematical models of varying complexity.
The talk will put the concept of digital twins into proper context with respect to manufacturing processes and both data-driven and model driven approaches will be discussed. The recent trend of incorporating advanced microscale characterization and modelling for prediction of macroscale behavior will also be illustrated by an example from casting.

Jesper H. Hattel obtained his M.Sc. in structural engineering in 1989 and his Ph.D. in mechanical engineering in 1993 both from the Technical University of Denmark (DTU). He currently holds a full professorship in modeling of manufacturing processes at the Dept. of Mechanical Engineering, DTU. His research interests are modeling of processes like casting, joining, composites manufacturing and additive manufacturing. This involves the use of computational methods within the disciplines of heat transfer, fluid dynamics, solid mechanics as well as materials science.
09:40 - 10:15
Digital process control and digital twins in foundries

Niels Skat Tiedje, Associate Professor, DTU Mechanical Engineering

This presentation will give examples from research projects at DTU Mechanical Engineering and some of our partner universities will be used to show how digital sensors and optical scanning can be used to monitor and analyze foundry processes.

We will show how online monitoring in combination with structured experiments can be used to make relatively simple models that are useful for controlling and predicting effects of process parameters on the production output. Furthermore, we will look at how 3D optical scanning can be used to analyze precision in the manufacturing process.

Niels Tiedje has worked as Associate Professor at DTU, Dept. of Mechanical Engineering since 1999. His field of researched is within solidification processes, solidification metallurgy and powder metallurgy and experimental research combined with thermodynamic and through process modelling. He has published 56 papers in recognized international journals.
10:15 - 10:30
10:30 - 11:05
Integrated modeling of the casting and heat treatment process chain - current trends and examples from industry

Jesper Thorborg, Head of R&D, MAGMA GmbH, Denmark

Integrated modeling of the casting process and the subsequent manufacturing steps is a growing field in the industry. This is particularly the case for cast and heat treated parts where stress analysis is used for process optimization to provide improved solutions in casting design and product quality.
This presentation will give recent examples with trends from the automotive industry and a small look into the background of the applied methods.

Jesper Thorborg has been with MAGMA GmbH since 2001 and works presently as Team Leader Solver, R&D projects and Software Development. Jesper also works as Affiliated Senior Researcher at DTU Mechancial Engineering.
11:05 - 11:40
Digitalization of metal - Why and how: What may and has been achieved by making metal digitally capable and traceable

Raul Carlsson, Senior Researcher, RISE Research Institute of Sweden

What are the main drivers for digitalizing and digiting metal? Mega trends surrounding the concept of sustainable development such as climate change, social responsibility and resource efficiency establish a market for better understanding and utilizing the value of materials. Our era of digitalization shows how the globally abundant material silicon contributes to expontential value increase of any aspect of our civilization’s businesses, behaviour and artefacts.

What if we look more closely at metal with the perspective of the endless capabilities of digitalization and digitization? What if we can trace any piece of metal? What if any piece of metal can be digitally active, like a sensor? What additional value would that provide? Is it even possible?

This presentation will show how we started to show that it is possible.

Raul Carlsson, Senior researcher at RISE - Research Institutes of Sweden, PhD Environmental sciences and MSc Engineering physics, Winner Swedish Association of Foundries 2019 Innovation Award for the innovation of smart castings with sensors. Innovator and researcher in the field of industrial sustainability informatics since the mid 1990s. Expert sustainability and environmental management, environmental performance evaluation, circular economy and sustainability innovation.
11:40 - 11:50
Closing remarks

Smart casting processes – establishing digital twins based on advanced sensors and models

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Registration fee

 DKK  1,095  Members of ATV-SEMAPP and promoting partners
 DKK  1,395  Non-members
 DKK    695  PhD Students
 DKK    200  BSc and MSc students (Membership is free of charge – register here. Early bird discount does not apply)

All prices are exclusive of 25 % VAT.

Early bird discount of DKK 300 when registering before 9 April 2021.

Binding registration
Registration is binding, however substitutions are accepted at any time. Just remember to let us know who will be replacing you so we know who to expect.

If you have any questions regarding the seminar, you can write to us here. We will get back to you quickly.