Analysis of HPDC Process with Automobile Part (Oil Pan) by CAE Simulation

2013 ◽  
Vol 753-755 ◽  
pp. 1318-1323 ◽  
Author(s):  
Kwang Kyu Seo ◽  
Hong Kyu Kwon
Keyword(s):  
Die Casting ◽  
Simulation Software ◽  
Filling Process ◽  
Solidification Shrinkage ◽  
Automobile Part ◽  
Computer Aided ◽  
Gate System ◽  
Simulation Results ◽  
Casting Design ◽  
Cae Simulation

In this research, Computer Aided Engineering (CAE) simulation was performed by using the simulation software (AnyCasting) in order to optimize casting design of an automobile part (Oil Pan_7G9E) which is well known and complicated to achieve a good casting layout. The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system.

Simulation Study and Application on HPDC Process with Automobile Part

2013 ◽  
Vol 658 ◽  
pp. 281-286 ◽  
Author(s):  
Kwang Kyu Seo ◽  
Hong Kyu Kwon
Keyword(s):  
Simulation Software ◽  
Steering Wheel ◽  
Filling Process ◽  
Solidification Shrinkage ◽  
Automobile Part ◽  
Computer Aided ◽  
Gate System ◽  
Simulation Results ◽  
Casting Design ◽  
Cae Simulation

In this research, Computer Aided Engineering (CAE) simulation was performed by using the simulation software (Z-Cast) in order to optimize casting design of an automobile part (steering wheel housing) which is well known and complicated to achieve a good casting layout. The simulation results were analyzed and compared with experimental results. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system.

Simulation Study on HPDC Process for Automobile Part with Aluminum Alloy

2013 ◽  
Vol 761 ◽  
pp. 79-82 ◽  
Author(s):  
Hong Kyu Kwon ◽  
Kwang Kyu Seo
Keyword(s):  
Die Casting ◽  
Simulation Software ◽  
Filling Process ◽  
Solidification Shrinkage ◽  
Cooling Systems ◽  
Automobile Part ◽  
Gate System ◽  
Simulation Results ◽  
Pressure Die Casting ◽  
Casting Design

In this research, in order to optimize casting design of an automobile part (Gear Box), Computer Aided Engineering (CAE) was performed by using the simulation software (Z-Cast). The simulation results were analyzed and compared with experimental results. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making better permanent High Pressure Die Casting (HPDC) mold, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

Simulation Analysis of HPDC Process with Automobile Part by CAE

2014 ◽  
Vol 804 ◽  
pp. 315-318
Author(s):  
Hong Kyu Kwon ◽  
Boong Joo Lee
Keyword(s):  
Simulation Analysis ◽  
Casting Process ◽  
Simulation Software ◽  
New Production ◽  
Automobile Part ◽  
Casting System ◽  
Gate System ◽  
Development Paradigm ◽  
Casting Design ◽  
Cae Simulation

In present casting industries, product development paradigm is shifting from traditional trial-and-error to proof-of-concept based on CAE-enabled simulation. In the new production development paradigm, CAE simulation plays an important role because it models the entire casting process and reveals the dynamic behavior of the casting system in working conditions. In this research, Computer Aided Engineering (CAE) simulation was performed by using the simulation software (AnyCasting) in order to optimize casting design of an automobile part (Upper Oil Pan) which is well known and complicated to achieve a good casting layout. The simulation results were analyzed and compared carefully in order to apply them into the production die-casting mold. During the filling process, internal porosities caused by air entrapments were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were also predicted.

The CAE Simulation of the Printer Cover Panel with Gas-Assisted Injection Molding

2012 ◽  
Vol 201-202 ◽  
pp. 808-811
Author(s):  
Guo Qiang Zhang ◽  
Mei Ting Xie ◽  
Wen Juan Wang ◽  
Ji Qiang Zhai
Keyword(s):  
Numerical Simulation ◽  
Injection Molding ◽  
Production Process ◽  
Process Parameters ◽  
Filling Process ◽  
Molding Process ◽  
Computer Aided ◽  
Simulation Results ◽  
Cae Technology ◽  
Cae Simulation

Numerical simulation in the printer cover product molding process with gas assisted injection molding was carried out by means of computer aided engineering. The filling process and surface quality were forecasted. The simulation results provide an important reference for the selection in the production process parameters. Compared with the production molding process and the actual product, CAE technology used in actual production and design is entirely feasible.

Study and Application of CAE Simulation in Die-Casting Die Design

2011 ◽  
Vol 101-102 ◽  
pp. 990-993
Author(s):  
Zhi Xin Jia ◽  
Ji Qiang Li ◽  
Li Jun Liu
Keyword(s):  
Numerical Analysis ◽  
Die Casting ◽  
Die Design ◽  
Filling Process ◽  
Die Casting Die ◽  
Temperature Distributions ◽  
Solidification Processes ◽  
Simulation Results ◽  
Cae Simulation ◽  
Filling And Solidification

The CAE simulations of filling and solidification processes for die-casting are studied. Numerical analysis is presented for a practical die-casting part using HZ CAE software. The temperature distributions and filling states in solidification and filling process are presented. Then the deficiencies of the part are predicted. Based on the analyzing results, the two die halves are modified and the die-casting parameters are adjusted. The service life of the revised die is increased from 12,000 shots to 20,000shots. It is proved that CAE simulation results can offer a helpful reference for die-casting die design.

Numerical Simulation Software of Casting Process used for Computer Aided Instruction

2011 ◽  
Vol 399-401 ◽  
pp. 13-16
Author(s):  
Jian Min Zeng ◽  
Jie Liang ◽  
Zhi Liu Hu ◽  
Ping Chen ◽  
Li Hua Liang
Keyword(s):  
Numerical Simulation ◽  
Casting Process ◽  
Simulation Software ◽  
Computer Aided Instruction ◽  
Casting System ◽  
Computer Aided ◽  
Solidification Processes ◽  
Software Utility ◽  
Casting Design ◽  
Filling And Solidification

Simulation software is an essential tool for today‘s engineers. Its application enables castings to be designed with predicting the final results prior to they are produced. Thus, the simulation plays significant role in casting production. If a realistic calculation of the mold filling and solidification processes can be made it is possible to predict casting defects caused by casting system and/or casting design. In order to understand the changes occurring during solidification of casting, numerical simulation has been used in our classroom teachings for postgraduates. The software structures, mathematical principles, software utility, functions and output criteria are introduced in this paper to demonstrate that computer aided instruction is of Intuitive, attractive and can be used in classroom before the real experiments as assistant means to help postgraduates to understand what is casting and what is solidification

Computer Aided Local Modifications for the Transition From Part Design to Die Design

1994 ◽  
Author(s):  
Shao-Chiung Lu ◽  
R. Allen Miller ◽  
Gary L. Kinzel
Keyword(s):  
Product Design ◽  
Die Casting ◽  
Geometric Reasoning ◽  
Die Design ◽  
Die Geometry ◽  
Cad System ◽  
Design Database ◽  
Computer Aided ◽  
Original Part ◽  
Casting Design

Abstract For a consistent die casting product design database, the die geometry should be generated from and be associated with the original part design. However, the original part design must be modified to include several process specific features, e.g. parting line, drafts, and rounds/fillets, before the creation of the die cavity. This paper deals with the incorporation of automatic/semi-automatic geometric modifications with drafts and rounds/fillets in a CAD system to smooth the transition from part design to die design. The underlying physical concerns behind these local geometric modifications are studied. The significant geometric characteristics in determining the appropriate size of drafts and rounds/fillets are then identified and extracted with geometric reasoning methods. This paper also presents the problems should be noted in applying these modifications to a die casting design.

Numerical Simulation Life Prediction of Alu- Alloy Die -Casting Dies

2012 ◽  
Vol 472-475 ◽  
pp. 2296-2303
Author(s):  
Xiong Wei Han ◽  
De Ping Chen
Keyword(s):  
Numerical Simulation ◽  
Thermal Stress ◽  
Life Prediction ◽  
Die Casting ◽  
Mathematic Model ◽  
Simulation Software ◽  
Mold Surface ◽  
Casting Technology ◽  
Stress Changes ◽  
Simulation Results

Abstract: The die casting technology has more wide application in the production of a variety of small appliances and cooking utensils. However, it is difficult to set casting technology parameters, and the life of casting die is short. In this study, the numerical simulation software was employed to simulate the aluminum mold. By analyzing temperature field, the temperature changes of the mould surface were predicted in the die-casting cycle. According to the thermal stress simulation and mathematic model, the thermal stress and strain variations were presented in the process of casting, The thermal stress changes of A, B point on the mold surface were compared under the different pouring temperature, die preheat temperature and cooling water temperature. On the basis of the simulation results, the best die casting technology parameters were selected. The life of die casting dies is predicted by mathematical model, and the simulation results agree well with the result of experiment. This study reached the conclusion is that the die life prediction method is reliable.

Numerical Simulation of Die-Casting Mold Filling Process by Using Fractional Step Method

2008 ◽  
Vol 575-578 ◽  
pp. 104-108
Author(s):  
Jie Yang ◽  
Yu Xin Ren ◽  
Shou Mei Xiong
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
Mold Filling ◽  
Flow Patterns ◽  
Fractional Step ◽  
Filling Process ◽  
Step Method ◽  
Fractional Step Method ◽  
Time Step ◽  
Simulation Results

In the numerical simulation of mold filling process, the calculation efficiency has been a key point for practical applications due to the complexity and thin-section of die castings. In current research work, a fractional step method was applied in the solution of the unsteady Navier-Stokes equations, which can be implemented with a single solution to the momentum/pressure equations at each time step. This method may avoid the decrease in efficiency induced by iteration. A water analog system was designed and developed to simulate the die casting process. The flow patterns were recorded by a high speed camera with a capturing rate of 500 frames per second. The simulation results were consistent with the experimental ones. Besides, the fluid flow patterns of several components were simulated by the fractional step and VOF algorithm, and the SOLA-VOF algorithm respectively. The simulation results showed that the combination of the fractional step method and VOF method can improve the computational efficiency to some extent in numerical simulation of mold filling process.

Sign in / Sign up

Export Citation Format

Share Document