scholarly journals Assessment of Computer Simulation Software and Process Data for High Pressure Die Casting of Magnesium

2007 ◽  
Author(s):  
Adrian S Sabau ◽  
Edward C Hatfield ◽  
Ralph Barton Dinwiddie ◽  
Kazunori Kuwana ◽  
Valerio Viti ◽  
...  
Keyword(s):  
Computer Simulation ◽  
High Pressure ◽  
Die Casting ◽  
Simulation Software ◽  
Process Data ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

Simulation of High Pressure Die Casting Solidification

2006 ◽  
Vol 508 ◽  
pp. 555-560 ◽  
Author(s):  
Dániel Molnár ◽  
Jenő Dúl ◽  
Richárd Szabó
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
High Pressure Die Casting ◽  
Die Casting Process ◽  
The University ◽  
Pressure Die Casting

By the help of simulation software it is possible to follow and predict the high pressure die casting process. In the Department of Foundry Engineering at the University of Miskolc, Hungary we use both Finite Element- and Finite Difference programs for simulation. In this paper we examine a special specimen, a plate with knobs, witch has point symmetric hot spots and cored parts which effect the characteristic of flow and solidification. We examined the solidification process and the temperature distribution. We determined that the finite element method, because of the meshing and the calculation mode, is more suitable for the simulation of thermal processes.

scholarly journals Analysis and Optimisation of High Pressure Die Casting Parameters to Achieve Six Sigma Quality Product Using Numerical Simulation Approach

2021 ◽  
Vol 11 (1) ◽  
pp. 97-109
Author(s):  
Suraj R. Marathe ◽  
Dr. Carmo E. Quadros
Keyword(s):  
Numerical Simulation ◽  
High Pressure ◽  
Molten Metal ◽  
Die Casting ◽  
Injection Pressure ◽  
Simulation Software ◽  
Holding Time ◽  
Simulation Approach ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

A numerical simulation approach is proposed to predict the optimal parameter setting during high pressure die casting. The contribution from the optimal parameters, the temperature, showed more influence on the casting quality than the other parameters. This study’s outcome was beneficial for finding the solution for casting defects that occurs due to incorrect setting of process parameters in die casting. Thus, a combination of numerical optimisation techniques and casting simulation serves as a tool to improve the casting product quality in die casting industries. This paper aims to analyse and optimise critical parameters like injection pressure, molten metal temperature, holding time, and plunger velocity, contributing to the defects. In this research paper, an effort has been made to give optimal pressure, temperature, holding time, and plunger velocity parameters using ProCAST simulation software that uses finite element analysis technology. Numerical analysis for optimising the parameters by varying the temperature of molten metal, injection pressure, holding time, and plunger velocity,  concerning solidification time at hot spots, is an essential parameter for studying the defect analysis in the simulated model.

A Development of Virtual Manufacturing System for Magnesium High Pressure Die Casting Processes

Materials ◽  
2003 ◽  
Author(s):  
Weilong Chen
Keyword(s):  
High Pressure ◽  
Magnesium Alloys ◽  
Die Casting ◽  
Virtual Manufacturing ◽  
Mold Design ◽  
High Pressure Die Casting ◽  
Molten Magnesium ◽  
Pressure Die Casting ◽  
Soft And Hardware ◽  
Free Magnesium

In recent years, high-pressure die-casting magnesium components have been gaining currency worldwide because of the excellent properties that magnesium alloys can offer to meet new product requirements. With the increasing application of magnesium parts worldwide, many research and development projects have been carried out to advance HPDC technology. However, truly optimized mold design and production of defect free castings remains a challenge for die casters. For many HPDC magnesium products, especially those specified for porosity-free and high cosmetic requirement, the challenge not only comes form a lack of a deeper understanding of how molten magnesium alloys fill the mold cavity and form defects, but also from improper preliminary part design. This study proposes a virtual prototyping system that integrates several effective soft and hardware tools for both the part and mold-design engineer to evaluate part manufacturability. Also, investigated in this study are the major causes of those defects that are the predominant cause of rejection of thin walled, leak-free magnesium parts requiring highly cosmetic finishes.

scholarly journals On the Use of Conformal Cooling in High-Pressure Die-Casting and Semisolid Casting

Technologies ◽  
2021 ◽  
Vol 9 (2) ◽  
pp. 39
Author(s):  
Anders E. W. Jarfors ◽  
Ruslan Sevastopol ◽  
Karamchedu Seshendra ◽  
Qing Zhang ◽  
Jacob Steggo ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Life Extension ◽  
Conformal Cooling ◽  
High Pressure Die Casting ◽  
Cooling Channels ◽  
Die Life ◽  
Die Materials ◽  
Pressure Die Casting ◽  
Semisolid Casting

Today, tool life in high pressure die casting (HPDC) is of growing interest. A common agreement is that die life is primarily decided by the thermal load and temperature gradients in the die materials. Conformal cooling with the growth of additive manufacturing has raised interest as a means of extending die life. In the current paper, conformal cooling channels’ performance and effect on the thermal cycle in high-pressure die casting and rheocasting are investigated for conventional HPDC and semisolid processing. It was found that conformal cooling aids die temperature reduction, and the use of die spray may be reduced and support the die-life extension. For the die filling, the increased temperature was possibly counterproductive. Instead, it was found that the main focus for conformal cooling should be focused to manage temperature around the in-let bushing and possibly the runner system. Due to the possible higher inlet pressures for semisolid casting, particular benefits could be seen.

Failure analysis of H13 steel die for high pressure die casting Al alloy

2021 ◽  
pp. 105330
Author(s):  
Rengen Ding ◽  
Haibo Yang ◽  
Shuzhi Li ◽  
Guodong Wu ◽  
Jiahao Mo ◽  
...  
Keyword(s):  
High Pressure ◽  
Failure Analysis ◽  
Die Casting ◽  
Al Alloy ◽  
H13 Steel ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

scholarly journals A digital twin approach to predict and compensate distortion in a High Pressure Die Casting (HPDC) process chain

2020 ◽  
Vol 52 ◽  
pp. 144-149
Author(s):  
Alireza Ebrahimi ◽  
Udo Fritsching ◽  
Michael Heuser ◽  
Dirk Lehmhus ◽  
Adrian Struß ◽  
...  
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Process Chain ◽  
High Pressure Die Casting ◽  
Digital Twin ◽  
Pressure Die Casting
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