Numerical Simulation of LPDC Process for Thin-Walled Aluminum Alloy

2012 ◽  
Vol 538-541 ◽  
pp. 474-478
Author(s):  
Li Qiang Zhang ◽  
Rong Ji Wang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Manufacturing Cost ◽  
Casting Quality ◽  
Filling Ability ◽  
Low Pressure Die Casting ◽  
Thin Walled ◽  
The Cost ◽  
Pressure Die Casting ◽  
Selection Of

In general, the thin-walled casting with the thickness less than 2mm is not easy to be prepared using low-pressure die casting (LPDC) technology because of its poor filling-ability. In this paper, the LPDC process of A356 thin-walled aluminum alloy was simulated based on the selection of appropriate boundary conditions in order to save the cost. The simulation results compared with experimental results indicate the numerical simulation technology is an effective tool for reducing the manufacturing cost and improving the casting quality.

Design of LPDC Process for Thin-Walled Casting Based on Numerical Simulation

2012 ◽  
Vol 217-219 ◽  
pp. 1786-1790
Author(s):  
Li Qiang Zhang ◽  
Rong Ji Wang
Keyword(s):  
Numerical Simulation ◽  
Aluminum Alloy ◽  
Boundary Conditions ◽  
Process Parameters ◽  
Casting Process ◽  
Manufacturing Cost ◽  
Simulation Technology ◽  
Thermal Boundary Conditions ◽  
Thin Walled

The LPDC process parameters of A356 thin-walled aluminum alloy were designed based on numerical simulation by precisely setting the thermal boundary conditions. By applying the designed process parameters, a sound casting with 300mm in length, 100mm in width and 1.5mm in thickness was successfully prepared. The results indicate the numerical simulation technology is an effective tool for designing casting process and reducing the manufacturing cost.

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.

Numerical Simulation of Filling for 7075 Alloy and TiB2/7075 Composites Wheel Prepared by Low Pressure Die Casting

2014 ◽  
Vol 904 ◽  
pp. 173-179
Author(s):  
Qian Gao ◽  
Bin Yang ◽  
Gui Sheng Gan ◽  
Huan Chun Wu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Mold Temperature ◽  
Low Pressure ◽  
Shrinkage Porosity ◽  
Physical Parameters ◽  
Pouring Temperature ◽  
Low Pressure Die Casting ◽  
7075 Alloy ◽  
Pressure Die Casting

Based on the experimental and calculation results between the reinforcing particles content and thermal physical parameters, low pressure die casting of wheels was taken as an example to study the casting property of the 7075 alloy and TiB2/7075 composites. The influences of die temperature, pouring pressure, pouring temperature and TiB2 content on the filling of 7075 alloy and TiB2/7075 composites wheels are studied by numerical simulation. Shrinkage porosity appears both in the spoke and rim of the wheel. The shrinkage porosity of the 7075 alloy decreases from 2.089% to 1.622% with mold temperature increasing from 100°C to 400°C. The shrinkage porosity of wheel decreases from 1.630% to 1.598% and 1.583% in the composite with 3 and 6wt.% TiB2 particles. Besides, shrinkage porosities decrease with increasing pouring temperature.

Numerical simulation of low pressure die casting of magnesium wheel

2006 ◽  
Vol 32 (3-4) ◽  
pp. 257-264 ◽  
Author(s):  
Ying-chun Wang ◽  
Da-yong Li ◽  
Ying-hong Peng ◽  
Xiao-qin Zeng
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Low Pressure ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

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.

Robust Tolerance Design With the Integer Programming Approach

1997 ◽  
Vol 119 (4A) ◽  
pp. 603-610 ◽  
Author(s):  
Chang-Xue (Jack) Feng ◽  
A. Kusiak
Keyword(s):  
Integer Programming ◽  
Loss Function ◽  
Programming Approach ◽  
Manufacturing Cost ◽  
Tolerance Design ◽  
Quality Loss ◽  
Quality Loss Function ◽  
The Cost ◽  
Manufacturing Yield ◽  
Selection Of

The quality loss function incorporates the cost of tolerances, however, it does not consider the manufacturing cost and design constraints. In this paper, a stochastic integer programming (SIP) approach is presented for simultaneous selection of tolerances and manufacturing processes. A direct link between the minimum manufacturing cost and the required level of manufacturing yield is established through the process capability index Cpk. As the tolerances in SIP are discrete, the solution generated is acceptable for manufacturing. It is shown that the integer programming models are applicable in the quality loss function and six sigma design approaches. The SIP approach is illustrated with a classical example of nonlinear tolerance design. The comparison of the proposed SIP approach, the Taguchi method, and the conventional mathematical models in tolerance synthesis is presented.

Rheology Forming Process of Cast Aluminum Alloys with Electromagnetic Applications

2006 ◽  
Vol 116-117 ◽  
pp. 445-448 ◽  
Author(s):  
T.W Kim ◽  
C.G. Kang ◽  
S.S. Kang
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Gas Content ◽  
Cast Aluminum ◽  
Forming Process ◽  
Cast Aluminum Alloys ◽  
Low Pressure Die Casting ◽  
Thin Walled ◽  
Semi Solid ◽  
Pressure Die Casting

This paper focuses on a rheo-forming of arm parts fabricated by an electromagnetic stirring system (EMS). This forming process takes place under high pressure of high pressure die casting and thin-walled casting is possible. Also, the productivity is higher than for low pressure die casting because of the shorter cycle time. Rheo-forming is advantageous because forming is performed in the semi-solid state with laminar flow and the gas content is low, which makes welding possible. Therefore, this paper examines arm parts with EMS and has investigated the mechanical properties after T6 and T5 heat-treatment.

Energy Absorption of Thin-Walled Square Tubes With a Prefolded Origami Pattern—Part I: Geometry and Numerical Simulation

2013 ◽  
Vol 81 (1) ◽  
Author(s):  
Jiayao Ma ◽  
Zhong You
Keyword(s):  
Numerical Simulation ◽  
Energy Absorption ◽  
Plastic Hinge ◽  
Thin Sheet ◽  
Manufacturing Cost ◽  
Developable Surface ◽  
Absorption Increase ◽  
Collapse Mode ◽  
Wide Range ◽  
Thin Walled

Thin-walled tubes subjected to axial crushing have been extensively employed as energy absorption devices in transport vehicles. Conventionally, they have a square or rectangular section, either straight or tapered. Dents are sometimes added to the surface in order to reduce the initial buckling force. This paper presents a novel thin-walled energy absorption device known as the origami crash box that is made from a thin-walled tube of square cross section whose surface is prefolded according to a developable origami pattern. The prefolded surface serves both as a type of geometric imperfection to lower the initial buckling force and as a mode inducer to trigger a collapse mode that is more efficient in terms of energy absorption. It has been found out from quasi-static numerical simulation that a new collapse mode referred to as the completed diamond mode, which features doubled traveling plastic hinge lines compared with those in conventional square tubes, can be triggered, leading to higher energy absorption and lower peak force than those of conventional ones of identical weight. A parametric study indicates that for a wide range of geometric parameters the origami crash box exhibits predictable and stable collapse behavior, with an energy absorption increase of 92.1% being achieved in the optimum case. The origami crash box can be stamped out of a thin sheet of material like conventional energy absorption devices without incurring in-plane stretching due to the developable surface of the origami pattern. The manufacturing cost is comparable to that of existing thin-walled crash boxes, but it absorbs a great deal more energy during a collision.

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