Integration between reverse engineering and high-pressure die casting simulation for optimisation of the manufacturing process for a gearbox housing of an electric vehicle.

The thesis work explores the synergy between Reverse Engineering (RE) and High Pressure Die Casting (HPDC) simulation of a gearbox housing of an electric vehicle. The goal of the research activity is to show the advantages of Computer Aided Engineering (CAE) and to demonstrate how it can be used in Automotive industry to reverse engineer the already existing parts. The 3D Computer Aided (CAD) model obtained through RE is used to perform the casting simulation to optimise the overall manufacturing process. The real part is scanned using FreeScan Combo, a handheld scanner developed by Shining 3D. The 3D point cloud data is then post processed in Geomagic Design X to obtain the 3D CAD model which can be used for further optimisation in terms of manufacturing cost, time, and material requirement. The HPDC simulations performed in Inspire Cast results in filling and solidification analysis. The results obtained from these analyses can be used to improve the product quality by minimising the potential casting defects or to highlight the area prone to casting defects like gas porosity, solidification porosity, and cold shuts. The quality of the casted part depends highly on optimised runner and gating system design. This requires a lot of experience since the process can be very complicated for parts with complex topology. However, the North American Die Casting Association (NADCA) offers guidelines for designing the runner and gating system. In this study, these standards are used as a reference to set up the HPDC simulation and properly design the optimised runner and gating system for casting of aluminium A380. The integration of reverse-engineered models into the HPDC simulation process facilitates a holistic approach to manufacturing optimisation. By leveraging these combined computer aided methodologies, the thesis aims to achieve improved part quality, reduced manufacturing time, and minimised material waste in the die casting process. This interdisciplinary investigation serves as a valuable resource for industries engaged in high-pressure die casting, guiding practitioners and researchers toward more efficient and cost-effective manufacturing practices. The findings offer insights into the integration of advanced technologies and promoting sustainable environment-friendly manufacturing processes.