scholarly journals CONTROL AUTOMATION OF DIE CASTING PROCESS WITH CRYSTALLIZATION

2018 ◽  
Vol 2018 (7) ◽  
pp. 32-43
Author(s):  
Максим Денисов ◽  
Maksim Denisov ◽  
Владимир Коростелев ◽  
Vladimir Korostelev
Keyword(s):  
Chemical Properties ◽  
Casting Process ◽  
Metal Structure ◽  
Pressure Application ◽  
Manufacturing Process Control ◽  
Control Automation ◽  
Die Casting Process ◽  
Metal Pressure ◽  
Metal Structure And Properties ◽  
Object Of Control

As an object of control there is a process of pressure application upon melt under consideration. In the course of metal pressure shaping the atoms ap-proach takes place at the elimination of some heat so that changes of a value and a speed of pressure applica-tion ensure atom approaches for different distances of elastic repulsive force actions till crystallization begin-ning. A possibility of accumulation and changes of in-teratomic interaction elastic energy in molten metal is considered as a fundamental basis for the change of metal structure and properties connected with it. The-reupon at the study of the process it is necessary to determine significant factors and their impact upon casting properties and on the basis of the mathematical description to determine laws of control. In the paper it is shown that pressure application is possible to a melt according to a certain law, before crystallization beginning, at the expense of modern control equipment and automation means use. This process represents a high significance in the creation of modern systems for manufacturing process control with the purpose of obtaining new kinds of materials with a specified combination of physical-chemical properties.

scholarly journals Experimental and numerical investigations of oxide-related defects in Al alloy gravity die castings

2021 ◽  
Author(s):  
Giulia Scampone ◽  
Raul Pirovano ◽  
Stefano Mascetti ◽  
Giulio Timelli
Keyword(s):  
Fluid Dynamic ◽  
Casting Process ◽  
Numerical Code ◽  
Al Alloy ◽  
Numerical Investigations ◽  
Die Casting Process ◽  
Experimental Findings ◽  
Die Castings ◽  
Filling And Solidification ◽  
Image Analysis Techniques

AbstractThis research aimed to study the formation and distribution of oxide-related defects in the gravity die casting process of an AlSi7Cu0.5Mg alloy by using experimental and numerical investigations. Metallographic and image analysis techniques were conducted to map the distribution of oxide inclusions inside the casting at the microscopic level. Numerical simulations were used to analyse the filling and solidification stages, and to foresee the turbulence of the melt and the formation of the oxide defects. The results show that most of the defects were correlated with the oxide layers or bubbles entrained inside the liquid metal. The accuracy of the numerical code in simulating the metal fluid-dynamic behaviour and the heat transfer was verified, and the results were in agreement with the experimental findings. The numerical distribution of defects was consistent with the experimental results, proving that the model successfully predicted the formation of oxide-related defects.

scholarly journals Heat Transfer Coefficient Determination in a Gravity Die Casting Process with Local Air Gap Formation and Contact Pressure Using Experimental Evaluation and Numerical Simulation

2021 ◽  
Author(s):  
T. Vossel ◽  
N. Wolff ◽  
B. Pustal ◽  
A. Bührig-Polaczek ◽  
M. Ahmadein
Keyword(s):  
Heat Transfer ◽  
Contact Pressure ◽  
Local Heat Transfer ◽  
Casting Process ◽  
Local Heat ◽  
Air Gap ◽  
Gap Formation ◽  
Transfer Coefficients ◽  
Heat Transfer Coefficients ◽  
Die Casting Process

AbstractAnticipating the processes and parameters involved for accomplishing a sound metal casting requires an in-depth understanding of the underlying behaviors characterizing a liquid melt solidifying inside its mold. Heat balance represents a major factor in describing the thermal conditions in a casting process and one of its main influences is the heat transfer between the casting and its surroundings. Local heat transfer coefficients describe how well heat can be transferred from one body or material to another. This paper will discuss the estimation of these coefficients in a gravity die casting process with local air gap formation and heat shrinkage induced contact pressure. Both an experimental evaluation and a numerical modeling for a solidification simulation will be performed as two means of investigating the local heat transfer coefficients and their local differences for regions with air gap formation or contact pressure when casting A356 (AlSi7Mg0.3).

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.

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