Compute-Aided Design of Low Pressure Die-Casting Process of A356 Aluminum Wheels

2017 ◽  
Vol 864 ◽  
pp. 173-178 ◽  
Author(s):  
Pei Hsing Huang ◽  
Wei Jen Wu ◽  
Chung Han Shieh
Keyword(s):  
Traffic Safety ◽  
Lightweight Design ◽  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Low Pressure Die Casting ◽  
Retained Melt Modulus ◽  
Porosity Defects ◽  
A356 Aluminum ◽  
Pressure Die Casting

The lightweight design of aluminum automobile wheel can easily bring about all kinds of defects during die-casting, which often causes wheel frame deformation and creep damages in the future use and in turn affects traffic safety. To understand the evolution of mold flow, temperature field, and solidification, the low pressure die-casting processes of A356 aluminum wheel were simulated by Anycasting software package. Various casting parameters combined with the designs of flow channel and overflows were adopted to reduce the defects occurred in wheel products. In addition, we adopted the retained melt modulus (RMM) to predict the position of defects to be formed as well as their distribution so as to eliminate the shrinkage voids and porosity defects during die-casting. The research findings showed that the setting up of overflow tank could effectively prevent the formation of shrinkage void and porosity of die-castings and significantly promote the quality and productivity of die-casting wheel products.

Numerical Simulations of Low Pressure Die-Casting for A356 Aluminum Rims

2017 ◽  
Vol 893 ◽  
pp. 276-280 ◽  
Author(s):  
Pei Hsing Huang ◽  
Wei Jen Wu ◽  
Chung Han Shieh
Keyword(s):  
Die Casting ◽  
Low Pressure ◽  
Optimization Of Process Parameters ◽  
Low Pressure Die Casting ◽  
Retained Melt Modulus ◽  
Porosity Defects ◽  
A356 Aluminum ◽  
Die Castings ◽  
Pressure Die Casting

This study conducted mold flow analyses on low pressure die-casting A356 aluminum rims to improve the shrinkage and porosity defects which usually occurs in die-castings so as to enhance the quality of die-casting wheels. We adopted different lift tube designs with cylindrical, taper opening and back taper opening structures while discussing the filling, exhaust, and solidification of molten flows and predicting the shrinkage and porosity formed based on the retained melt modulus. The study found that the configuration of lift tube as well as the optimization of process parameters such as the processing pressure and progressive time could effectively reduce the formations of shrinkage and porosity defects and improve the quality of die-castings.

Numerical Study on the Low Pressure Die Casting of AZ91D Wheel Hub

2005 ◽  
Vol 488-489 ◽  
pp. 393-396 ◽  
Author(s):  
Ying Hong Peng ◽  
Da Yong Li ◽  
Ying Chun Wang ◽  
Ji Long Yin ◽  
Xiao Qing Zeng
Keyword(s):  
Cooling System ◽  
Numerical Study ◽  
Liquid Fraction ◽  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Cooling Capacity ◽  
Simulation Software ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

Most magnesium alloy components available for automobile are made through die casting. In this paper, PAM-CASTTM, commercial die casting simulation software based on the finite difference method, is employed to simulate the low-pressure die casting process of magnesium wheel hub. The temperature field and velocity field during filling and solidification stages are analyzed; the evolution of temperature distribution and liquid fraction was numerically studied. Then, the potential defects including the gas entrapments in the middle of the spokes, shrinkages between the rim and the spokes are predicted. The cooling performance of mould during casting is also investigated. Via analyzing the shrinkage defects generated under various cooling conditions, the cooling system set in the side mould is found to be more effective for enhancing the cooling capacity at the rim/spoke junction areas. With this cooling system, the hot spots at the junctions are obviously reduced and product quality is improved.

Development of an Innovative Low Pressure Die Casting Process for Aluminum Powertrain and Structural Components

2018 ◽  
Vol 21 (6) ◽  
pp. 1800105 ◽  
Author(s):  
Mikel Merchán ◽  
Pedro Egizabal ◽  
Maider García de Cortázar ◽  
Ane Irazustabarrena ◽  
Haize Galarraga
Keyword(s):  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Structural Components ◽  
Low Pressure Die Casting ◽  
Die Casting Process ◽  
Pressure Die Casting

Full through Process Simulation for Low Pressure Die Casting – From Casting to Design

2014 ◽  
Vol 794-796 ◽  
pp. 118-123 ◽  
Author(s):  
Amir M. Horr ◽  
Christoph Angermeier ◽  
Angela Harrison
Keyword(s):  
Process Simulation ◽  
Driving Forces ◽  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Fluid Simulation ◽  
Experimental Program ◽  
Interactive Simulation ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

To achieve a required product quality during Low Pressure Die Casting (LPDC) process, it is necessary to identify and also control the main input parameters affecting the casting defects to arrive at the desired output quality. In industrial scale LPDC, where the issues of part quality, cost, and cast speed are the main driving forces for the industries, the cast process optimization to have minimum defects is quite essential. The LPDC process of light weight metals is defined as a casting process where the die is filled relatively slowly at low pressure. The melt flow regime has low turbulence, and filling process can be defined as relatively smooth filling. In recent years, in order to limit the component defects, the through process simulation has widely been used. In an interactive simulation environment, a full multi-phase casting process simulation (thermal-fluid simulation using multi-physical domain) along with its material and mechanical simulations are carried out in a single environment. One of the main contributions of this paper is to show the advantages of using full through process simulation of LPDC to limit the defect in the component. An experimental program along with a comprehensive process simulation has been setup to optimize the casting process and the results were presented for real world case studies.

scholarly journals EFFECTS OF AIR-COOLING-HOLE GEOMETRIES ON A LOW-PRESSURE DIE-CASTING PROCESS

2021 ◽  
Vol 55 (4) ◽  
Author(s):  
Ugur Pehlivanoglu ◽  
Tugce Yagci ◽  
Osman Culha
Keyword(s):  
Experimental Design ◽  
Alloy Steel ◽  
Die Casting ◽  
Casting Process ◽  
Low Pressure ◽  
Cooling Power ◽  
Cavity Surface ◽  
Air Cooling ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

A significant precondition for the production of high-quality castings is keeping an optimum temperature of the respective parts of the die cavity surface. This temperature depends on the temperature of the material, the quantity of metal, the method of cooling the casting die, the thermal conductivity of the die material, and the time during which the casting remains in the die. In addition, the cooling characteristics of alloy steel dies, used in the production of aluminum-alloy wheels with the low pressure die casting (LPDC) method, have critical effects on the mechanical and metallurgical properties of the product. Ducted air coolers are widely used for the cooling of these alloy steel dies. However, the geometrical designs of the air-cooling holes are limited. In this study, we define the effects of the geometry of the cooling holes on the cooling power of the die, the efficiency of the air consumption with the Full Factorial Experimental Design method and to determine the optimum values for LPDC. Pilot production has been carried out on an industrial scale to verify the data obtained by experimental design. The experimental and real data were compared based on the values of the yield strength and the secondary dendrite arm spacing in the microstructure.

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