scholarly journals Molten metal velocities and gas pressures in die cavity of commercial aluminum pressure die-casting.

1988 ◽  
Vol 38 (3) ◽  
pp. 129-133 ◽  
Author(s):  
Yoshiaki YAMAMOTO ◽  
Yasushi IWATA ◽  
Katsutoshi TOZAWA ◽  
Motoyuki NAKAMURA
Keyword(s):  
Molten Metal ◽  
Die Casting ◽  
Pressure Die Casting ◽  
Gas Pressures

On the Critical Plunger Speed and Three-Dimensional Effects in High-Pressure Die Casting Injection Chambers

2003 ◽  
Vol 125 (3) ◽  
pp. 529-537 ◽  
Author(s):  
J. Lo´pez ◽  
F. Faura ◽  
J. Herna´ndez ◽  
P. Go´mez
Keyword(s):  
Molten Metal ◽  
Cross Section ◽  
Die Casting ◽  
Three Dimensional ◽  
Circular Cross Section ◽  
Water Model ◽  
Two Dimensional ◽  
Shallow Water Model ◽  
One Dimensional ◽  
Pressure Die Casting

During the initial slow stage of the injection process in high-pressure die casting machines with horizontal cold chamber, a plunger pushes the molten metal which partially fills the injection chamber, causing the formation of a gravity wave. The evolution of the wave surface profile, which depends on the plunger acceleration law, may trap air in the molten metal, causing porosity when the metal solidifies. In this work, a one-dimensional shallow-water model, which is solved numerically using the method of characteristics, and a three-dimensional numerical model, based on a finite element formulation and the volume of fluid (VOF) method for treating the free surface, are used to analyze the flow of molten metal in an injection chamber of circular cross section. The results for the evolution of the free surface obtained from both models for different plunger motion laws and initial filling fractions of the injection chamber were in good agreement for broad ranges of operating conditions. The existence of a critical plunger speed, above which the reflection of the wave of molten metal against the chamber ceiling might appreciably increase air entrapment effects, is investigated. The results for the wave profiles in chambers of circular cross section are compared with those obtained in an equivalent two-dimensional configuration of the injection chamber, for which the shallow-water model is solved analytically. It is shown how the results obtained by applying the one-dimensional model to a two-dimensional chamber configuration can be used to reproduce, with an acceptable degree of accuracy, the salient characteristics of the flow of molten metal in a real injection chamber of circular cross section.

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.

Numerical Simulation of Back Pressure Influenced Aluminum Component’s HPDC Process

2010 ◽  
Vol 139-141 ◽  
pp. 549-552 ◽  
Author(s):  
Wen Jiong Cao ◽  
Zhao Yao Zhou ◽  
Yi He ◽  
Yuan Biao Wu
Keyword(s):  
Molten Metal ◽  
Flow Behavior ◽  
Die Casting ◽  
Back Pressure ◽  
Filling Process ◽  
Porosity Defects ◽  
Simulation Results ◽  
Pressure Die Casting ◽  
Residual Air ◽  
Actual Part

Due to the flow behavior of molten metal is affected by the back pressure of mold residual air in high pressure die casting (HPDC) process, the back pressure conditions should be considered in order to simulate the HPDC process precisely. In this study, an aluminum colander of automobile’s filling process in HPDC was calculated by combining the back pressure conditions. The optimized schemes were given by considering the simulation results. Both initial and optimized schemes simulation results were compared with actual parts. The contribution of gas porosity between simulation and actual part were in agreement when back pressure conditions were applied. The local back pressure can be controlled by coordinating the position of the vents. Therefore the flow behavior of molten metal can be changed and the porosity defects can be fixed.

Optimum Runner Design for Die Casting Using CFD Simulations and Verification With Water-Model Experiments

2014 ◽  
Author(s):  
Ken’ichi Kanazawa ◽  
Ken’ichi Yano ◽  
Jun’ichi Ogura ◽  
Yasunori Nemoto
Keyword(s):  
Molten Metal ◽  
Die Casting ◽  
Air Entrainment ◽  
Optimization Method ◽  
Water Model ◽  
Cfd Simulations ◽  
Mathematical Functions ◽  
Model Experiments ◽  
Runner Design ◽  
Pressure Die Casting

This study aimed to optimize the design of a runner for high-pressure die casting (HPDC) using computational fluid dynamics (CFD) simulations, and to verify the effectiveness of the runner with water-model experiments. A runner is a part of the flow path through which molten metal enters a product part. As a design problem, we sought to optimize the shape of the runner to minimize air entrainment in the runner and align the flow of molten metal after it passed through the runner. The problem was solved using our proposed nonparametric shape optimization method. The method is based on a genetic algorithm (GA), and directly treats a geometric shape that is comprised of several curves as an individual of a GA in the form of a set of mathematical functions. In addition, the crossover, which is one of the genetic operations, is defined as a weighted summation of two parent curves. Thus, the optimization method can generate optimized shapes with a lot of flexibility. The effectiveness of the optimized shape of the runner was demonstrated with both CFD simulations and water-model experiments using a visualization device for HPDC.

scholarly journals Effect of mold designs on molten metal behaviour in high-pressure die casting

2017 ◽  
Vol 822 ◽  
pp. 012029 ◽  
Author(s):  
M D Ibrahim ◽  
M R A Rahman ◽  
A A Khan ◽  
M R Mohamad ◽  
M S Z M Suffian ◽  
...  
Keyword(s):  
High Pressure ◽  
Molten Metal ◽  
Die Casting ◽  
High Pressure Die Casting ◽  
Pressure Die Casting

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.

Sign in / Sign up

Export Citation Format

Share Document