Studies on the Cooling Effects of Water Cooling Channels in Die Casting Die in Finite Element Method

2012 ◽  
Vol 500 ◽  
pp. 397-402 ◽  
Author(s):  
Xin Ping Hu ◽  
Juan Zhang ◽  
Da Wei Lu ◽  
Wen Jun Min
Keyword(s):  
Temperature Field ◽  
Die Casting ◽  
Water Channel ◽  
Cooling Water ◽  
Casting Process ◽  
Water Cooling ◽  
Cooling Channels ◽  
Die Casting Die ◽  
Cooling Effects ◽  
Die Temperature

Die casting is a high productive method to produce non ferrous castings such as Al, Mg alloy. And die temperature field paid important effects on the casting quality and die life. Die temperature field was controlled mainly by water cooling channel in die. In this paper, some factors influenced the die temperature such as the temperature of cooling water, the location of cooling water channel, the diameter of cooling water channel, the amount of cooling water channel were discussed and analyzed by FEM. These results are very practical in die casting process.

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.

Numerical Simulation Investigation on the Temperature Field Distribution and Variations in Hot Stamping Process

2010 ◽  
Vol 44-47 ◽  
pp. 992-996
Author(s):  
Lei Zhang ◽  
Guo Qun Zhao ◽  
Hui Ping Li
Keyword(s):  
Temperature Field ◽  
Field Distribution ◽  
Hot Stamping ◽  
Water Channel ◽  
Cooling Water ◽  
Temperature History ◽  
Temperature Field Distribution ◽  
Finite Element Software ◽  
Stamping Process ◽  
Die Surface

With finite element software Abaqus, a coupled thermal mechanical simulation of hot stamping process of U-Channel part using high strength steel was performed. Through the analysis of the temperature field distribution on the die surface, the influence of contact state between die and blank on the temperature field distribution was discussed. With temperature history curve of a selected node on die corner, the heat flow on two contact boundaries (die surface and cooling water channel surface) was discussed and its effects rules on the die temperature were given.

scholarly journals Experimental and Theoretical Studies on the Effect of Die Temperature on the Quality of the Products in High-Pressure Die-Casting Process

2012 ◽  
Vol 2012 ◽  
pp. 1-9 ◽  
Author(s):  
Mohammad Sadeghi ◽  
Jafar Mahmoudi
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Casting Process ◽  
Initial Step ◽  
Experimental Sample ◽  
Melt Temperature ◽  
High Pressure Die Casting ◽  
Die Temperature ◽  
The Difference ◽  
Pressure Die Casting

Die temperature in high-pressure die casting of A380 alloy is optimized by experimental observation and numerical simulation. Ladder frame (one part of the new motor EF7) with a very complicated geometry was chosen as an experimental sample. Die temperature and melt temperature were examined to produce a sound part. Die temperatures at the initial step and the final filling positions were measured and the difference between these values was calculated. ProCAST software was used to simulate the fluid flow and solidification step of the part, and the results were verified by experimental measurements. It is shown that the proper die temperature for this alloy is above 200°C.

scholarly journals Manufacturing of High Pressure Die Casting Die Inserts Using SLM

2020 ◽  
Author(s):  
Roland Stolt ◽  
Anders E.W. Jarfors
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Steel Powder ◽  
Rough Machining ◽  
High Pressure Die Casting ◽  
Manufacturing Method ◽  
Cooling Channels ◽  
Die Casting Die ◽  
Current Design ◽  
Pressure Die Casting

Dies for high pressure die casting are normally manufactured by machining of slabs of tool steel to the required dimensions. This manufacturing requires several steps such as rough machining, heat-treatment, EDM (electro discharge machining) and polishing. With the AM (additive manufacturing) method SLM (Selective Laser Melting) it has become possible to print the dies fully or in part. Several advantages are expected, such as a better thermal distribution in the die in service and thereby extended die life and better component quality. This is due to the possibility of making the cooling channels conformal. There are also expectations of reduced time and cost in the manufacturing process due to fewer manufacturing steps and better material utilisation. Hopes are to print a net shape or near net shape that can be used directly as a die component. In this paper it is investigated to what extent this can be fulfilled by printing two die inserts to be used for casting fatigue test samples of aluminium. They were printed on a 3D Systems ProX DMP 300 in maraging steel powder. The result is that it is possible to obtain a sufficiently smooth surface die surface. However, the current design with an SLM insert fitted in a machined die makes extensive post printing manufacturing necessary.

A Correlation Analysis of Cooling-Induced Temperature Changes

2008 ◽  
Vol 131 (1) ◽  
Author(s):  
Tiebao Yang ◽  
Henry Hu ◽  
Xiang Chen ◽  
Yeou-li Chu ◽  
Patrick Cheng
Keyword(s):  
Water Temperature ◽  
Temperature Control ◽  
Linear Time ◽  
Cooling Water ◽  
Casting Process ◽  
Temperature Control System ◽  
Outlet Temperature ◽  
Local Surface ◽  
Cooling Water Temperature ◽  
Die Temperature

Proper temperature control is essential for producing superior quality components and yielding high production rates in high temperature manufacturing processes. Due to the closure of machine tools such as casting dies during production, it is usually very difficult to monitor their local surface temperatures without destructively inserting thermal sensors into them. However, the measurement of cooling water temperature at the coolant outlet is relatively unproblematic. This work demonstrates that there is a correlation between these two temperatures. As an example, the effect of the local surface temperature of a casting die on the cooling water outlet temperature is analyzed from a laboratory die casting process simulator. Based on the system identification theory, a control-oriented linear time-invariant model has been developed, which correlates the local die temperature to the cooling water outlet temperature. The model enables the prediction of the local die temperature with the measurements of the cooling water temperature. Thus, it provides an alternative approach other than the destructive sensing method to acquire the local die temperatures, and the model could be applied to design a real-time temperature control system for die cooling 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.

A system for computer-aided gating design for multi-cavity die-casting dies

2015 ◽  
Vol 231 (11) ◽  
pp. 1983-1999 ◽  
Author(s):  
Vijay Kumar ◽  
Jatinder Madan
Keyword(s):  
System Design ◽  
Computer Aided Design ◽  
Die Casting ◽  
Casting Process ◽  
Manufacturing Cost ◽  
Gating System ◽  
Industrial Case Study ◽  
Efficient Manner ◽  
Die Casting Die ◽  
Computer Aided

The gating system design for a die-casting die is a non-trivial task that involves a number of steps and computations, in which many factors related to part design, material, and process need to be accounted. In case of a multi-cavity die-casting die, the non-triviality of the gating system design increases manifold. The main contribution of this article is to develop a computer-aided system for design of gating system for multi-cavity die-casting dies. The proposed system applies design knowledge and rules, accounting for various influencing factors to design gating system elements and generate their computer-aided design models in an efficient manner. To demonstrate the capabilities of the developed system, the results for an industrial case study part are presented. We expect that the proposed system would help reduce manufacturing cost and lead time, alongside bridging gaps between design and manufacturing of the die-casting process.

Thermal Crown Analysis of the Roll Sleeve in Twin-Roll Strip Casting Process

2013 ◽  
Vol 395-396 ◽  
pp. 936-940
Author(s):  
Hai Tao Cui ◽  
Guo Dong Wang
Keyword(s):  
Heat Flux ◽  
Cooling Water ◽  
Casting Process ◽  
Strip Casting ◽  
Finite Element Program ◽  
Cooling Channels ◽  
Cooling Water Temperature ◽  
Thermal Crown ◽  
Element Program ◽  
Twin Roll

In the twin-roll strip casting process, analyses of heat transfer and deformation for the casting roll sleeve are carried out by using the finite element program ANSYS to examine the the thermal crown. The effects of several factors such as molten pool temperature, heat flux onto the roll surface and roll edge, heat flux onto the cooling channels, and cooling water temperature on thermal crown are investigated. The results show that the thermal crown does not change sharply during the casting process, after the casting roll reaches thermal equilibrium.

Casting Process Optimization for Large Bearing Bush of Zinc-Base Alloy

2011 ◽  
Vol 704-705 ◽  
pp. 40-44
Author(s):  
Cun Zhen Gao ◽  
Di Xin Yang ◽  
Jing Pei Xie ◽  
Ai Qin Wang ◽  
Wen Yan Wang
Keyword(s):  
Numerical Simulation ◽  
Temperature Gradient ◽  
Base Alloy ◽  
Cooling Water ◽  
Solidification Process ◽  
Casting Process ◽  
Water Cooling ◽  
Metal Core ◽  
Metal Solidification ◽  
Water Rate

The numerical simulation of temperature gradient in the solidification process for large bushing castings of zinc-base alloy was made with HUAZHU CAE/Inte-CAST10.0 software in this paper. Tendency and the position of shrinkage were predicted,and the effect of cooling water rate and cooling time on temperature gradient and shrinkage during the molten metal solidification was discussed. The results show that:seting chilled iron at bottom of bearing bush and using water-cooling metal core in inner cavity of casting simultaneously, can eliminated shrinkage hole and porosity.

The Methods of Extending the Serve Life of Die Casting Dies in Industry Domain

2012 ◽  
Vol 487 ◽  
pp. 375-378
Author(s):  
Hua Qing Lai
Keyword(s):  
Material Selection ◽  
Die Casting ◽  
Casting Process ◽  
Mold Design ◽  
Treatment Technology ◽  
Casting Mold ◽  
Die Casting Die ◽  
Heat Treatment Technology ◽  
Die Life ◽  
Processing Material

Analysis of the casting mold in the casting process of the failure of several major forms of the structure from the die casting and die-casting mold design, manufacturing and processing, material selection, heat treatment technology and the use of die-casting mold, and other aspects of maintenance and maintenance to improve die-casting die life way.

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