Casting and Machining Process Analysis at GM Powertrain

GM Powertrain has been applying CAE methods to casting and machining process design for over 10 years, and currently has approximately 20 manufacturing engineers doing analysis work full time. This paper describes application experience in four areas: Casting solidification, casting flow/mold filling, machining process simulation, and finite element applications. In each area, the issues which can be investigated analytically are described, along with the input information required and the programs currently used. Each section concludes with application case studies which demonstrate how CAE methods can be used to improve quality and cut production cost.