Numerical Modeling of the Structural Behavior of Thin-Walled Cast Magnesium Components Using a Through-Process Approach

A through-process methodology for numerical simulations of the structural behavior of thin-walled cast magnesium components is presented. The methodology consists of casting process simulations using MAGMAsoft, mapping of data from the process simulation onto a FE-mesh (shell elements) and numerical simulations using the explicit FE-code LS-DYNA. In this work, generic High Pressure Die Cast (HPDC) AM60 components have been studied using 3-point bending and 4-point bending tests. The experimental data are applied to obtain a validated methodology for finite element modeling of thin-walled cast components subjected to quasi-static loading. The cast magnesium alloy is modeled using a user-defined material model consisting of an elastic-plastic model based on a non-associated J2-flow theory and the Cockcroft-Latham fracture criterion. The fracture criterion is coupled with an element erosion algorithm available in LS-DYNA. The constitutive model and fracture criterion are calibrated both with data from material tests and data from the process simulation using MAGMAsoft.