Shell Die-Casting and its Process Based on Numerical Simulation

2011 ◽  
Vol 233-235 ◽  
pp. 1167-1170 ◽  
Author(s):  
Yao Huang ◽  
Yue Dong ◽  
Yong Huang
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Casting Process ◽  
Velocity Fields ◽  
Shrinkage Cavity ◽  
Variation Trend ◽  
Casting Technology ◽  
Simulation Results ◽  
Die Casting Process ◽  
Temperature And Velocity Fields

In this paper, the distribution and variation trend of temperature and velocity fields were obtained by numerical simulation of the casting process of shell die casting. According to the results of the numerical simulation, the die casting technology was optimized. The sound castings were produced. It was verified that shrinkage cavity and porosity could be reduced by increasing injected pressure and decreasing pouring and mould temperatures. The reliability of numerical simulation of die casting process was proved. In addition, the qualified products were obtained on the basis of the optimized die-casting parameters from the simulation results.

Numerical Simulation on Filling Optimization of Copper Rotor for High Efficient Electric Motors in Die Casting Process

2017 ◽  
Vol 898 ◽  
pp. 1163-1170
Author(s):  
Ya Nan Wu ◽  
Guo Jie Huang ◽  
Lei Cheng ◽  
Daniel Liang ◽  
Wei Xiao
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Casting Process ◽  
Filling Process ◽  
Technological Parameters ◽  
Filling Time ◽  
High Efficient ◽  
Simulation Results ◽  
Die Casting Process ◽  
Cold Chamber

The parametric optimization of process parameter in cold chamber die casting for an industrial component (copper motor rotors) was analyzed. The filling process was successfully simulated based on software FLOW-3D. The distribution of gas entrapment, temperature field and surface defect during the mold filling process were discussed in details. The numerical results showed that the pouring velocity had the most significant influence on the filling time, followed by the filling temperature and the die temperature. As for the filling properties, the effect of the pouring temperature was dominant. From the simulation results, the places of defect in the copper rotor were forecasted, and the reasons of the defect were well explained. Thus, the technological parameters could be improved in numerical simulation, and the simulation results would be further validated in practice.

Study on Local Extrusions' Effects on Improvement of Die Casting Prismatic Parts' Forming Quality

2013 ◽  
Vol 312 ◽  
pp. 475-479
Author(s):  
Wei Gang Zheng ◽  
Cun Hong Yin ◽  
Yu Hong Yuan ◽  
Zhen Min Pan ◽  
Chao Tang
Keyword(s):  
Mechanical Properties ◽  
Die Casting ◽  
Casting Process ◽  
Extrusion Process ◽  
Shrinkage Porosity ◽  
Shrinkage Cavity ◽  
Prismatic Parts ◽  
Porosity Defects ◽  
Die Casting Process ◽  
Casting Production

This paper analyzes traditional die casting process to find out the reasons that cause shrinkage cavity and porosity defects in casting. An optimized process of die casting by using local extrusion is proposed. A device used in local extrusion which realizes forcing compensating contraction on key parts of crankcase is designed and the parameters of local extrusion process are discussed. Compared the mechanical properties and microstructure of local extrusion used in die casting production with traditional. It shows that local extrusion used in die casting production can not only achieve the aim eliminating shrinkage porosity and cavity of a casting but also can refine grain to improve the mechanical properties.

Numerical Simulation on the Filling Process of Rheological Die Casting and Forming Defects Analysis

2012 ◽  
Vol 192-193 ◽  
pp. 293-298 ◽  
Author(s):  
Fan Zhang ◽  
Nan Nan Song ◽  
Jun Zhang ◽  
Yong Lin Kang ◽  
Qiang Zhu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Solid Particles ◽  
Filling Process ◽  
Die Casting Process ◽  
Defects Analysis ◽  
Semi Solid ◽  
Forming Defects

According to semi-solid slurry rheological behavior, an apparent viscosity model of A356 alloy developed based on the Carreau model was established to simulate filling process of rheo-diecasting about automobile shock absorber parts and to compare with conventional liquid filling process. Numerical simulation results showed that the filling process of rheo-diecasting was smooth but difficult to splash, which reduced the tendency of the alloy oxidation and inclusion. Meanwhile, a certain percentage of the primary solid particles precipitated before filling and solidification shrinkage of semi-solid slurry were small. This benefited to reduce or eliminate shrinkage defects of the castings. Compared with conventional liquid die casting process, rheo-diecasting process had unique advantages in reducing the internal defects and improving mechanical properties of castings.

Application of Numerical Simulation Technology on the Design of Camera Shell during Die Casting Process

2007 ◽  
Vol 26-28 ◽  
pp. 1041-1044
Author(s):  
Hong Yan ◽  
Zhi Hu ◽  
Ti Shuan Suan
Keyword(s):  
Numerical Simulation ◽  
Material Science ◽  
Die Casting ◽  
Casting Process ◽  
Practical Result ◽  
Die Casting Process ◽  
Computer Numerical Simulation ◽  
The Cost ◽  
Pressure Die Casting

The technology of computer numerical simulation on casting process is an important frontal field of material science and technology. The numerical simulations of camera shell in the pressure die casting process were carried out. The distributions of temperature and solidification time in the filling process were obtained. Based on the simulated results and the Niyama criterion G/ R , the positions of slack were predicted, which were agreement with the practical result. Consequently, an improved scheme was presented, in which the workpiece defects were obviously reduced. So it’s significant for the application of numerical simulation on improving the quality of the casting, shortening the period of producing, reducing the cost and guiding the engineer for taking reasonable method to optimize the technological design.

Floating Behavior of Entrapped Gas in Semi-Solid Metal

2017 ◽  
Vol 898 ◽  
pp. 1254-1260
Author(s):  
Hong Xing Lu ◽  
Qiang Zhu ◽  
Da Quan Li ◽  
Fan Zhang
Keyword(s):  
Solution Heat Treatment ◽  
Die Casting ◽  
Casting Process ◽  
Acceptance Rate ◽  
Solid Metal ◽  
High Quality ◽  
Casting Technology ◽  
Die Casting Process ◽  
Semi Solid ◽  
Die Castings

Semi-solid die casting technology has great advantages at defects control and has been successfully used to produce high quality aluminum alloy components for several years. In this process, semi-solid metal with high apparent viscosity and low plunger velocity are used to avoid surface turbulence which is the main source of entrapped gas in conventional die casting processes. But, entrapped gas still has other sources, such as melting, pouring, surface flooding and confluence weld. Solution heat treatment is always used to strengthen semi-solid die castings. The entrapped gas leads to blister defects, which directly decreases the acceptance rate of semi-solid die castings. So, the entrapped gas is still a serious issue in semi-solid die casting process. We studied the floating behavior of entrapped gas bubble in semi-solid metal. Two floating models were established for gas bubbles with different sizes. These models were used to analyze the possibility of entrapped gas escaping from semi-solid metal in casting practice. The results showed that entrapped gas from feed billet could not escape from the semi-solid metal in the casting process of impeller, which was proved by experiment results. These results emphasized the importance of clean melt and semi-solid metal. Some advices were given at last for avoiding or removing the entrapped gas in semi-solid die casting process.

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.

Numerical Simulation and Process Optimization of Aluminum Alloy Connecting Rod Based on ProCAST

2013 ◽  
Vol 712-715 ◽  
pp. 549-552
Author(s):  
Hua Feng Lu ◽  
Rong Fa Chen ◽  
Yi Hong Zhao ◽  
Long Wu ◽  
Zhi Long Li ◽  
...  
Keyword(s):  
Aluminum Alloy ◽  
Die Casting ◽  
Casting Process ◽  
Casting Defects ◽  
Permanent Mold ◽  
Connecting Rod ◽  
Technical Requirements ◽  
Simulation Results ◽  
Die Casting Process ◽  
Filling And Solidification

The structural feature and technical indexes of 2A14 aluminum alloy connecting rod was analyzed. The pouring system of gravity die-casting process was initially designed according to the technical requirements. The gravity filling and solidification stages in the permanent mold were simulated by ProCAST. The simulation results show that the casting defects are predicted and the casting process are improved. The most possible section of crack defects are the transition part between the shaft and the connecting rod small or big end.

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