From casting to forging - The combined simulation for a steel component

In the aluminum sector as well as in the manufacture of semi-finished products, there are numerous industrial examples for combinations of casting and forming processes. In the past, the processes usually were considered separately. However, with the development of digital technologies, it has recently become possible to jointly simulate casting and forging processes and set up continuous process simulations. In the manufacturing of steel components, such a combination is not known industrially. The present paper describes a forged steel component based on a cast preform. To predict the expected properties, the necessary simulations were linked, whereby the focus of the investigations is on the principle feasibility and methodology of such a combination. Based on the conditions assumed in the simulations, test components were manufactured. The simulation results, especially voids and porosity were compared with the real components. In addition, the microstructure of the components was investigated. Approaches for further investigations and the improvement of the combined simulation are presented.