Fluid behavior control on die casting process by optimization of plunger tip shape based on practicable damage estimation algorithm

2013 ◽  
Author(s):  
Yuto Takagi ◽  
Yoshifumi Kuriyama ◽  
Ryota Sakamoto ◽  
Ken'ichi Yano ◽  
Shuhei Baba
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Estimation Algorithm ◽  
Damage Estimation ◽  
Behavior Control ◽  
Fluid Behavior ◽  
Die Casting Process

Development of Semi-Solid Die Casting Product Design and Die Design Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 256 ◽  
pp. 334-339 ◽  
Author(s):  
Song Chen ◽  
Fan Zhang ◽  
You Feng He ◽  
Da Quan Li ◽  
Qiang Zhu
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Thick Wall ◽  
Thin Wall ◽  
Gating System ◽  
Cross Sectional ◽  
Die Casting Process ◽  
Semi Solid

Semi-solid slurry has significantly higher viscosity than liquid metal. This character of fluidity makes product design and die design, such as gating system, overflow and venting system, be different between these two die casting processes. In the present paper, taking a clamp product as an example, analyses the product optimization and die design by comparing the experimental and computational numerical simulation results. For the clamp, product structure is designed to be suitable for characters of SSM die casting process. The gating system is designed to be uniform variation of thickness, making the cross-sectional area uniformly reduce from the biscuit to the gate. This design ensures semi-solid metal slurry to fill die cavity from thick wall to thin wall. Gate position is designed at the thickest location, the gate shape of semi-solid die casting is set to be much bigger than traditional liquid casting. A good filling behaviour can be achieved by aforementioned all these design principles and it will be helpful to the intensification of pressure feeding after filling.

Development of 2-Cavity Die Casting Process for AM50 Mg Steering Column Lock Housing Module

2006 ◽  
Vol 510-511 ◽  
pp. 334-337
Author(s):  
Shae K. Kim
Keyword(s):  
Magnesium Alloy ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
Weight Reduction ◽  
Die Casting ◽  
Casting Process ◽  
Research Strategy ◽  
Good Choice ◽  
Weight Basis ◽  
Die Casting Process

It is obvious that automotive industry worldwide is predicting significant growth in the use of magnesium alloys for weight reduction to decrease fuel consumption and emission. About a half decade ago, the price of magnesium alloys was more than twice that of aluminum alloys on a weight basis. Currently, magnesium alloys cost about one and a half times that of aluminum alloys on a weight basis, and thus the price of magnesium alloys is the same as or lower than that of aluminum alloys on a per volume basis. However, in considering the performance of magnesium components (not their specific mechanical properties) and recycling aspect of magnesium alloys, it is required to realize niche applications of magnesium alloys, which meet the cost requirement on performance basis and/or offer more than weight reduction. There are many other factors that make magnesium a good choice: component consolidation, improved safety for driver and passengers, and improved noise vibration and harshness (NVH), to name a few. As one of these efforts to adopt magnesium alloys in automotive component, this paper describes the research strategy of cold chamber type 2-cavity die casting of AM50 magnesium alloy for developing the steering column lock housing module with emphasis on cost driving factors and necessities for cost reduction, explaining why AM50 magnesium alloy is chosen with design and die casting process optimization.

Predicting heat extraction due to boiling in the cooling channels during the pressure die casting process

2000 ◽  
Vol 214 (3) ◽  
pp. 465-482 ◽  
Author(s):  
L D Clark ◽  
I Rosindale ◽  
K Davey ◽  
S Hinduja ◽  
P J Dooling
Keyword(s):  
Heat Transfer ◽  
Forced Convection ◽  
Die Casting ◽  
Casting Process ◽  
Nucleate Boiling ◽  
Heat Extraction ◽  
Film Boiling ◽  
Cooling Channels ◽  
Die Casting Process ◽  
Pressure Die Casting

The effect of boiling on the rate of heat extraction by cooling channels employed in pressure die casting dies is investigated. The cooling effect of the channels is simulated using a model that accounts for subcooled nucleate boiling and transitional film boiling as well as forced convection. The boiling model provides a continuous relationship between the rate of heat transfer and temperature, and can be applied to surfaces where forced convection, subcooled nucleate boiling and transitional film boiling are taking place in close proximity. The effects of physical parameters such as flow velocity, degree of subcooling, system pressure and bulk temperature are taken into account. Experimental results are obtained using a rig that simulates the pressure die casting process. The results are compared with the model predictions and are found to show good agreement. Instrumented field tests, on an industrial die casting machine, are also reported. These tests show the beneficial effects of boiling heat transfer in the pressure die casting process, including a 75 per cent increase in the production rate for the test component.

Semisolid Die-Casting Process of Mg-20Al-0.8Zn Magnesium Alloy

2011 ◽  
Vol 306-307 ◽  
pp. 539-543
Author(s):  
Feng Yun Yan ◽  
Xiao Feng Huang ◽  
Bo Li ◽  
Ying Ma
Keyword(s):  
Tensile Strength ◽  
Die Casting ◽  
Injection Pressure ◽  
Casting Process ◽  
Elongation Rate ◽  
Isothermal Heat Treatment ◽  
Technological Parameters ◽  
Injection Speed ◽  
Die Casting Process ◽  
Spherical Grains

Based on microstructure evolution of Mg-20Al-0.8Zn magnesium alloys realized by semisolid isothermal heat-treatment (SSIT), we obtained the non-dendrite or spherical grains microstructure under the suitable technological parameters that isothermal temperature is 495 °C and holding time is 120 min. With the help of special experimental equipment, the semisolid die-casting process has been studied and the specimens have been analyzed. The effects of different parameters as injection speed and pressure on tensile strength, elongation rate, hardness, etc have been investigated. The results indicate that tensile strength was improved along with increasing injection speed and pressure. However, excessive speed will involve gas, which formed defects and reduced the mechanical properties. When the injection pressure is 40MPa and injection speed is 4m/s, the tensile strength and elongation rate can reach maximal 220MPa and 5.63% respectively. Its fracture mechanism was intercrystalline cracking.

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