Experimental Investigation Into the Thermal Behavior of Copper-Alloyed Dies in Pressure Die Casting

2006 ◽  
Vol 128 (4) ◽  
pp. 844-859 ◽  
Author(s):  
L. D. Clark ◽  
M. T. Alonso Rasgado ◽  
K. Davey ◽  
S. Hinduja
Keyword(s):  
Thermal Resistance ◽  
Die Casting ◽  
Significant Proportion ◽  
Casting Machine ◽  
Experimental Results ◽  
Heat Extraction ◽  
Zinc Alloy ◽  
Experimental Investigations ◽  
Spray Process ◽  
Pressure Die Casting

The rate of heat extraction during the pressure die casting process is central to both the quality and the cost of finished castings. Recent efforts to reduce the thermal resistance of dies by optimizing the effectiveness of the cooling channels have shown the potential for improvement. Reducing the thermal resistance of the coolant boundary layer means that a significant proportion of the total thermal resistance becomes attributable to the die steel. Further significant reductions in die thermal resistance can be obtained by replacing the steel with copper. This paper investigates the feasibility of using copper dies, reinforced with steel inserts and coated with a thin layer of wear resistant material, which is deposited using the thermal arc spray process. Experimental work relating to the thermal spray process has been undertaken to establish bond strengths and thermal conductivities for various process parameters. Moreover, experimental investigations have been carried out using two copper coated dies, the first of which was a pseudodie block heated by an infrared heater. The second die was tested on a die casting machine and produced zinc alloy castings at a greatly increased production rate when compared to its steel counterpart. The experimental results from the two dies are compared with those predicted by an in-house thermal-cum-stress model based on the boundary element method. Reasonable agreement between the predicted and experimental results is shown and the feasibility of copper-alloyed dies for pressure die casting is established.

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.

scholarly journals Reduction of Blowholesin Aluminium High Pressure Die Casting Machine

2018 ◽  
Vol 7 (3.34) ◽  
pp. 410
Author(s):  
Nagasankar P ◽  
Sathiyamoorthy. V ◽  
Gurusamy. P ◽  
VinothKanna P ◽  
Manibharathi D ◽  
...  
Keyword(s):  
High Pressure ◽  
Manufacturing Process ◽  
Die Casting ◽  
Casting Machine ◽  
Casting Process ◽  
Magma Flow ◽  
High Pressure Die Casting ◽  
Analysis Technique ◽  
Quality Product ◽  
Pressure Die Casting

The main objective of this research is to reduce the blowholes by analyzing the factors which are affected during the casting process. The process parameters are optimized and change is made in the design part to reduce the blowhole and to increase the efficiency of the high pressure die casting machines. Product manufactured from every manufacturing process shows some defects. For supplying quality product to the customer these defects must be reduced. In this work, an attempt is made to reduce the rejection due to the blowhole defect is found out through why-why analysis technique. Process capability of current high pressure die casting manufacturing process is checked. Manufacturing process found capable to manufacture the components. Current problem of blowhole defect is solved making an improvement in design of die which we insert. In gate directions are changed so as to obtain modified improved flow pattern. Using magma flow simulationsoftware existing and modified design has then been compared. It is found that, modified design shows superior results and using this, the defect of blowholes is minimized up to satisfactory level.   

scholarly journals Deflection Simulation of a Die Installed in a High-Pressure Die-Casting Machine

2013 ◽  
Vol 79 (806) ◽  
pp. 3920-3929 ◽  
Author(s):  
Hiroshi YAMAGATA ◽  
Yoshiro SHIGENAGA ◽  
Shoji TANIKAWA ◽  
Makoto NIKAWA
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Casting Machine ◽  
High Pressure Die Casting ◽  
Pressure Die Casting
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