Instructed by Prof. von Grossmann and Prof. Hornfeck, a student group had the task to develop a two-cylinder model engine with integrated water cooling and to produce initial components. Beside the CAD- and CAE-software and a rapid prototyping wax thermal printer, Georg-Simon-Ohm University also has facilities for investment casting.
Full of energy and with many good ideas, the group started with the engine’s construction. Promptly the first problems occurred, which are also known to experienced engineers in practice - communication between design engineers and foundry turned out to be a problem. The tough timeline of approximately 10 weeks did not appear to be possible. Only with the introduction of a project manager was the project steered onto the right track and first prototypes could be poured as vacuum supported precision plaster castings. The simulations with MAGMASOFT® helped the students, who were inexperienced in foundry technology, to optimize the gating system and to analyze potential sources of problems such as hotspots.