Mitigating distortions in cast automotive subframes: A finite element simulation approach

Abstract Ensuring dimensional accuracy is critical for automotive parts, as they must meet strict tolerances - often within a few hundred microns at key locations to ensure proper assembly within the vehicle. However, the casting and heat treatment of large aluminium structures introduces thermal stresses and distortions that must be controlled to maintain these requirements. To address this challenge, a mathematical modeling based framework has been developed to predict and mitigate the deformations by designing the casting process along with the heat-treatment and quenching process. The simulations conducted, using an in-house developed Finite Element based solver, are validated against physical test data from industrial production. The comparisons show that the the models developed in this work, along with their underlying assumptions, provide a comprehensive representation of the thermo-mechanical behaviour of subframe parts during the casting process. Finally, further refinements to the modelling approach have been suggested to improve the test-simulation correlations.