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

scholarly journals ANALISIS GAGAL LEAK TEST PADA PRODUK CYLINDER HEAD TYPE-A HASIL PROSES LOW PRESSURE DIE CASTING DENGAN MATERIAL AC4B DI PT. X

Technologic ◽  
2020 ◽  
Vol 11 (2) ◽  
Author(s):  
Wahyudi Wahyudi ◽  
Slameto Wiryolukito
Keyword(s):  
Cylinder Head ◽  
Die Casting ◽  
Melting Furnace ◽  
Type A ◽  
Low Pressure ◽  
Shrinkage Porosity ◽  
Leak Test ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting ◽  
Head Type

Abstrak--Keadaan yang sedang terjadi pada seksi LPDC di PT. X adalah banyaknya cacat pada produk hasil casting sesuai data cacat pada bulan Januari-Juni 2018 yaitu persentase total cacat tertinggi sebesar 20.64% pada seksi LPDC In Plant dan Next Process di bulan April 2018. Jenis cacat tertinggi pada seksi LPDC In Plant adalah Misrun dinding chain sebesar 3.48% dan pada LPDC Next Process adalah gagal leak test sebesar 4.93%. Hal ini sangat merugikan perusahaan baik dalam biaya produksi yang meningkat dan waktu produksi yang lama. Karakterisasi yang dilakukan pada penelitian ini adalah pengujian leak lest, radiografi (x-ray), optical emission spectroscopy, penetrant, metalografi, SEM, dan uji EDS. Berdasarkan hasil dari karakterisasi yang diperoleh, menunjukkan bahwa produk gagal leak test mengalami cacat internal yaitu shrinkage porosity. Berdasarkan hasil analisis fenomena cacat shrinkage porosity tersebut disebabkan oleh adanya inklusi oksida aluminium yang terbawa ke dalam produk Cylinder Head Type-A yang menjadi inisiasi terbentuknya shrinkage porosity. Terdapatnya oksida aluminium pada produk Cylinder Head Type-A disebabkan oleh waktu transfer molten dari melting furnace yang relatif lama dan jarak auto carrier yang relatif tinggi sehingga turut mempengaruhi waktu pouring ke holding furnace. Kata Kunci: Cylinder Head, Low pressure die casting, leak test, shrinkage porosity, oksida.

Effects of Combination of 0.02 wt % Sr and Ti on the Characteristics of AC4B Alloys Produced by Low Pressure Die Casting

2014 ◽  
Vol 875-877 ◽  
pp. 1255-1259
Author(s):  
Bondan Tiara Sofyan ◽  
Muhammad A. Falah
Keyword(s):  
Cylinder Head ◽  
Die Casting ◽  
Maximum Level ◽  
Hardness Test ◽  
Low Pressure ◽  
Optical Microscope ◽  
Shrinkage Porosity ◽  
Grain Refiner ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

Aluminium AC4B alloy is widely used in automotive industries for various components. However, when this alloy is used to produce motorcycle cylinder head by Low Pressure Die Casting (LPDC) process, high reject rate was often found due to shrinkage, porosity and misrun. Addition of grain refiner and modifier is an alternative for this problem, through the control of solidification process that results in grain refining and microstructure modification. This study was aimed to investigate the effect of combination of 0.02 wt. % Sr modifier with variation of Ti grain refiner on the characteristics of AC4B alloy and the reject rate of cylinder head components. The Ti grain refiner was varied 0.063, 0.083 and 0.108 wt. % Ti and added at the holding furnace prior to LPDC process. A series of test was conducted including hardness test from the thin and thick regions of the part, tensile test, fluidity test, vacuum test as well as observation of microstructure by using optical microscope and Scanning Electron Microscopy (SEM) equipped with Energy Dispersive X-Ray Analysis (EDAX). The results showed that the higher the Ti content, the higher the hardness for both thin and thick areas, the lower the fluidity of the molten metal. At the maximum level of Ti of 0.108 wt. % and 0.02 wt. % Sr, the reject rate was significantly reduced from 3.59 % to 1.38 %.

Numerical Simulation for Low Pressure Die Casting of Al-Alloy Motor Enclosure and Technology Improvement

2008 ◽  
Vol 575-578 ◽  
pp. 1389-1395 ◽  
Author(s):  
Guo Fa Mi ◽  
Xiang Yu Liu ◽  
Kuang Fei Wang ◽  
Ji Tai Niu
Keyword(s):  
Numerical Simulation ◽  
Cooling System ◽  
Die Casting ◽  
Low Pressure ◽  
Simulation Software ◽  
Al Alloy ◽  
Distribution Rule ◽  
Technology Improvement ◽  
Low Pressure Die Casting ◽  
Pressure Die Casting

The FDM numerical simulation software, View-Cast system, was employed to simulate the mould-filling and solidification process in low pressure die casting (LPDC) of Al-alloy motor enclosure. The distribution of liquid fraction, temperature field and the solidification pattern of casting were revealed and the formation mechanism as well as distribution rule of the potential defects, namely gas pores and shrinkage pores, were predicted. Furthermore the solutions to eliminate them were presented. By reducing the pouring rate, the turbulent flow at the corner of casting had eased, so the gas pores could be eliminated. Then the force-cooling system was installed on the top of mould, which could reduce the volume of liquid islands efficiently so that the shrinkage defects can be decreased to its limit.

The Liquid Surface Pressure Control System for Low Pressure Die Casting Based on Fuzzy PID

2013 ◽  
Vol 706-708 ◽  
pp. 1063-1067
Author(s):  
Hai Feng Lin ◽  
Liu Qing Du ◽  
Li Ping Xiong
Keyword(s):  
Control System ◽  
Surface Pressure ◽  
Liquid Surface ◽  
Die Casting ◽  
Pressure Control ◽  
Low Pressure ◽  
Fuzzy Pid ◽  
Low Pressure Die Casting ◽  
Pressure Control System ◽  
Pressure Die Casting

The Liquid Surface Pressure Control is the key factor for the guarantee of Low Pressure Die Casting Quality. Regarding to the disadvantages of conventional PID Control such as pressure fluctuation, poor repeatability of the pressure curve, and so on, we propose Liquid Surface Pressure Control System (LSPCS) based on Fuzzy Adaptive PID. Design method of Fuzzy PID Controller has been discussed, and the realization methods of the hardware and software in this system are developed. This proposed system has a good performance in practice.

Application of Automobile Lightweight Alloys and the Development of its Die-Casting Technology

2011 ◽  
Vol 308-310 ◽  
pp. 785-789 ◽  
Author(s):  
De Fang Liu ◽  
Jie Tao
Keyword(s):  
Automotive Industry ◽  
Die Casting ◽  
Low Pressure ◽  
Development Trend ◽  
Casting Technology ◽  
Low Pressure Die Casting ◽  
Lightweight Alloys ◽  
Semi Solid ◽  
Pressure Die Casting ◽  
The Development Trend

With the development of lightweight vehicles, lightweight alloy materials has been increasingly used in automotive industry, automobile manufacturers are therefore looking for thinner and stronger materials so that the higher requirements has became a challenge to lightweight alloy die-casting technology. The paper summarized the applications of lightweight alloys in the automotive industry, and the new advances of lightweight alloys die-casting technology, such as low pressure die-casting, semi-solid die casting, oxygenation die-casting and the combination of different die-casting technologies, and discussed the development trend of the lightweight alloy die-casting technology.

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