scholarly journals Die Casting Die Design and Process Optimization of Aluminum Alloy Gearbox Shell

Materials ◽  
2021 ◽  
Vol 14 (14) ◽  
pp. 3999
Author(s):  
Mingyu Huang ◽  
Qian Zhou ◽  
Junyou Wang ◽  
Shihua Li
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Cooling System ◽  
Structural Characteristics ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Die Design ◽  
Production Cycle ◽  
Gating System

Taking an aluminum alloy gearbox of an automobile as an example, according to its structural characteristics, the parting surface was determined, and the initial gating system was designed by using 3D modeling software UG. Based on Magmasoft software, the numerical simulation of the filling and solidification process was carried out to determine the best gating system scheme. The cooling system and core pulling structure were designed, and the parameter design process of the aluminum alloy gearbox shell in the die-casting process was introduced. Aiming at the leakage problem of the gearbox shell in the bench and road test after assembly, the cause was found through numerical simulation and industrial CT analysis, and the problem was solved by adding high-pressure point cooling at the corresponding position of the leakage, and the correctness of the optimization was verified. It provides an effective method for the die-casting production of the transmission housing and the analysis and solution of product defects, which improves the product quality and shortens the production cycle.

Numerical Simulation and Production Trial of Aluminum Alloy Gear Box Housing

2014 ◽  
Vol 703 ◽  
pp. 232-236
Author(s):  
Li Yong Ni ◽  
Peng Liu
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Cooling System ◽  
Die Casting ◽  
Slag Inclusion ◽  
Simulation Software ◽  
Gating System ◽  
Die Castings ◽  
Filling And Solidification ◽  
Cold Lap

Die casting processing analysis was conducted and the gating system and the cooling system were designed for aluminum alloy gearbox housings. Numerical simulation software PROCAST was used to calculate the filling and solidification sequence and the temperature field of die castings. The reasonable designs of the gating system and the cooling system were obtained. The feasible die casting mould was designed and manufactured. Production trial showed that, casting molding effect is good, and there were not defects such as misrun, cold lap. After machining, there were not defects exceeding the allowed limited values including porosity, shrinkage, and slag inclusion in the products. The trial showed that the product mold design and die casting technology achieved the desired effect, which can realize batch production.

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.

Numerical Simulation of Mold Filling and Solidification Process of a Disc Aluminum Alloy in Pressure Die Casting

2011 ◽  
Vol 121-126 ◽  
pp. 254-258
Author(s):  
Bai Yang Lou ◽  
Fang Li Liu ◽  
Kang Chun Luo
Keyword(s):  
Numerical Simulation ◽  
Mathematical Model ◽  
Aluminum Alloy ◽  
Die Casting ◽  
Solidification Process ◽  
Mold Filling ◽  
Casting Defects ◽  
Casting Simulation ◽  
Pressure Die Casting ◽  
Filling And Solidification

The numerical simulations of mold filling and solidification process for the A380 aluminum alloy were done by the supposed mathematical model. The casting defects in the process of mold filling and solidification were predicted by the result of the casting simulation. The casting defects of simulation are well compared with the practice. Some measures presented were improved for the existing technological process.

Optimization of Tilt-Casting of Aluminum Alloy Automobile Drain Pipes through Numerical Simulation

2013 ◽  
Vol 762 ◽  
pp. 633-638
Author(s):  
Ye Wang ◽  
Shi Ping Wu ◽  
Xiang Xue ◽  
Jing Jie Guo
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Solidification Process ◽  
Casting Process ◽  
Test Methods ◽  
Orthogonal Test ◽  
Single Factor ◽  
Pouring Temperature ◽  
Preheating Temperature ◽  
Lower Temperature

The effect of major parameters, such as pouring temperature, tilt time and preheating temperature of mold, on the tilt casting of aluminum alloy automobile drain pipes is studied through numerical simulation using single factor and orthogonal test methods. The simulation results of single factor test indicate that the increase in the pouring temperature and mold preheating temperature could effectively reduce the shrinkage tendency and the shortage of tilt time would cause lower temperature gradient of casting at the beginning of solidification, thus would lead the extension of solidification time. And the results of orthogonal test showed that the sequence of factors having effect on the filling and solidification process, are pouring temperature, tilt time and preheating temperature of mold. Finally, combined the result of single factor test with orthogonal test, an optimized tilt-casting process was proposed by investigating the velocity distribution at each stage of the filling process and the isolated area distribution of liquid phase in the solidification process, and by predicting the position of porosity in the casting. The effectiveness of the proposed process parameters in producing high quality castings is also proved through numerical simulation.

Numerical Simulation and Die Casting Process for Cylinder

2012 ◽  
Vol 490-495 ◽  
pp. 2362-2365
Author(s):  
Yong Huang ◽  
Yue Dong ◽  
Xiao Ming Du
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Temperature Field ◽  
Die Casting ◽  
Casting Process ◽  
Processing Parameters ◽  
Mould Temperature ◽  
Pouring Temperature ◽  
Die Casting Process ◽  
Filling And Solidification

Filling and solidification for aluminum alloy packing block in die casting were simulated by numerical simulation. Distribution and change of temperature field as well as velocity field were visualized. The desirable processing parameters can be obtained with pouring temperature of 620°C and mould temperature of 180°C as well as shot velocity of 4m/s. The qualified products were obtained on the basis of the optimized die-casting parameters.

Application of Numerical Simulation on Cast-Iron Pneumatic Hammer Housing

2011 ◽  
Vol 474-476 ◽  
pp. 432-435
Author(s):  
Guo Fa Mi ◽  
Li Lin Chen ◽  
Bao Zhong Liu ◽  
Hai Yan Wang
Keyword(s):  
Numerical Simulation ◽  
Cast Iron ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
Gating System ◽  
Pneumatic Hammer ◽  
Shrinkage Defects ◽  
Simulation Results ◽  
D Model

The Pro/E software was used to generate 3-D model of pneumatic hammer housing casting. The solidification process of the casting was simulated by the numerical simulation software, View Cast. The location and scale of the shrinkage defects were shown in the results. The risers were designed by the View Cast software based on the simulation results. The reasonable risers were obtained after the optimization on the numerical simulation. And the parameters of gating system were got according to the simulation results calculated by the gating system designing function of View Cast. Then the solidification results demonstrated that the risers and pouring system could be planned by View Cast effectually. The reasonable casting process was obtained and the process has been proofed by the productive practice.

Numerical Simulation of Semi-Solid Die Casting Process of Magnesium Alloy

2011 ◽  
Vol 474-476 ◽  
pp. 255-259 ◽  
Author(s):  
Ya Ping Hu ◽  
Yong Hu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Flow Characteristics ◽  
Casting Process ◽  
Die Design ◽  
Filling Process ◽  
Die Filling ◽  
Gas Cavity ◽  
Die Casting Process ◽  
Semi Solid

Numerical simulation can be used to predict die filling, and hence to optimize the die design. In the study, the flow characteristics of liquid filling comparing with those of semi-solid filling were analyzed. The results indicated that the liquid filling turned out to be turbulent, while the semi-sold filling had laminar flow characteristics which could reduce the foundry defects such as gas cavity and oxidation mixture. The distribution of pressure reduced gradually in the filling direction during semi-solid filling process which would generate back pressure that was favorable for filling process.

Determination of Die Design Rules for Semi-Solid Die Casting Process and Its Experimental Investigation

2005 ◽  
Vol 475-479 ◽  
pp. 2533-2538 ◽  
Author(s):  
Chung Gil Kang ◽  
P.K. Seo ◽  
Byung Min Kim
Keyword(s):  
Heat Treatment ◽  
Die Casting ◽  
Casting Process ◽  
Die Design ◽  
Design Rule ◽  
Gating System ◽  
T6 Heat Treatment ◽  
Semi Solid ◽  
Line Design ◽  
Air Vent

Die design rule for semi-solid die casting (SSDC) with A356 electromagnetic stirring (EMS) aluminum alloy, was proposed. The die design rule included inspection of machine, part requirements, parting line determination, sleeve, plunger, gating system, overflow, air vent, ejector pin, and heating line design. The specification of gating system, overflow, air vent, plunger tip, and sleeve suitable for respective part were regulated. Two steps die system of lower-positioned gate and three steps die system of center-positioned gate were manufactured for 4 automobile suspension parts, based on the die design rule. For the sound filling pattern and solidification behavior, injection speeds of 4 parts were summarized to the interval (from V1 to V4). As a result of observing the microstructure of 4 parts after T6 heat treatment, primary Al-α phase was globularized and fine Si particles were distributed around the grain boundary. The mechanical properties of 4 parts with T6 heat treatment were investigated and showed ultimate tensile strength (UTS) of 330 MPa, yield strength (YS) of 250 MPa, and elongation of 7.5% as average.

Development of Semi-Solid Die Casting Process Technology for Aluminium Alloy Clamp

2016 ◽  
Vol 850 ◽  
pp. 642-648 ◽  
Author(s):  
Song Chen ◽  
Da Quan Li ◽  
Fan Zhang ◽  
You Feng He ◽  
Qiang Zhu ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Structure Optimization ◽  
Casting Process ◽  
New Product ◽  
Product Structure ◽  
Die Design ◽  
Design Parameters ◽  
Die Casting Process ◽  
Semi Solid

Compared with traditional liquid and solid processing methods, semi-solid die casting process can apparently overcome shrinkage cavity and porosity defects in castings and high deformation resistance and high residual stress shortcomings in forging parts. Semi-solid die casting process with advantages such as high efficiency and low cost, will become the optimal process for high quality automobile parts. In this study, using the clamp as an example, the author introduced product structure optimization and die design for semi-solid die-casting process of aluminum alloy in a new product development.The Computer Aided Engineering technology was applied to the product structure optimization according to the stress analysis. The optimal mold structure, including cavity layout, gating system, overflow and vent systems, were confirmed based on the die design criteria for traditional die casting, combining with the characteristics of semi-solid forming and the simulation results. The semi-solid aluminum alloy clamp parts with excellent performances were finally developed successfully by means of product structure optimization, die design, parameters optimization of die casting process, and the mechanical properties test of products.The existing parts were optimized to make them more suitable for semi-solid die casting processing. In addition, a reasonable die design specially for semi solid processing was an important guarantee for a successful semi solid product applied in industry. Computer numerical simulation was applied in product structure design for semi-solid die casting, die design, die-casting process optimization and other aspects, to shorten the development cycle of new product, reduce cost and improve efficiency.

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