Thermal Stress Analysis of the Die during High Pressure Casting

2014 ◽  
Vol 915-916 ◽  
pp. 1074-1077
Author(s):  
Wu Hu ◽  
Ming Long Kang ◽  
Jian Min Zeng
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Die Casting ◽  
The Other ◽  
Air Cooling ◽  
Pressure Casting ◽  
Cooling Channel ◽  
Finite Element Software ◽  
Efficient Measure ◽  
Pressure Die Casting

The distribution of temperatures and stresses in the die during high pressure die casting are computed through commercially finite element software developed by Wincast team, Germany. The deformation of the die during its continual running is predicted under the conditions without and with air cooling. The simulated results show that the regions of die, which contact with the casting, is subjected to compressed stresses and the other regions of the die subjected to tensile stresses. Compressed stresses are changed steeply from tensile to compress on the boundary between the casting and the inner cavity walls, which will results in hot-fatigue in those regions of the die. Setting cooling channel within the die is an efficient measure for eliminating hot-fatigue and prolonging life of the die.

scholarly journals Design optimization of gate system on high pressure die casting of AlSi13Fe alloy by means of finite element simulations

Procedia CIRP ◽  
2020 ◽  
Vol 88 ◽  
pp. 509-514
Author(s):  
Mohamad El Mehtedi ◽  
Tommaso Mancia ◽  
Pasquale Buonadonna ◽  
Leonardo Guzzini ◽  
Enrico Santini ◽  
...  
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Design Optimization ◽  
Die Casting ◽  
Finite Element Simulations ◽  
High Pressure Die Casting ◽  
Gate System ◽  
Pressure Die Casting

Simulation of High Pressure Die Casting Solidification

2006 ◽  
Vol 508 ◽  
pp. 555-560 ◽  
Author(s):  
Dániel Molnár ◽  
Jenő Dúl ◽  
Richárd Szabó
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Simulation Software ◽  
High Pressure Die Casting ◽  
Die Casting Process ◽  
The University ◽  
Pressure Die Casting

By the help of simulation software it is possible to follow and predict the high pressure die casting process. In the Department of Foundry Engineering at the University of Miskolc, Hungary we use both Finite Element- and Finite Difference programs for simulation. In this paper we examine a special specimen, a plate with knobs, witch has point symmetric hot spots and cored parts which effect the characteristic of flow and solidification. We examined the solidification process and the temperature distribution. We determined that the finite element method, because of the meshing and the calculation mode, is more suitable for the simulation of thermal processes.

scholarly journals Effect of parameters of high-pressure die casting on occurrence of casting nonconformities in sleeves of silumin alloy EN AB 47100

2017 ◽  
Vol 62 (1) ◽  
pp. 373-378
Author(s):  
Ł. Pałyga ◽  
M. Stachowicz ◽  
K. Granat
Keyword(s):  
High Pressure ◽  
Die Casting ◽  
Casting Machine ◽  
Pressure Casting ◽  
High Pressure Die Casting ◽  
Closing Force ◽  
Working Parameters ◽  
Shrinkage Cavities ◽  
Pressure Die Casting ◽  
Selection Of

Abstract The paper presents a research on the effect of extreme - for the technology of the considered silumin EN AB 47100 - parameters of high-pressure die casting on occurrence of casting nonconformities. Considered was influence of the way of assembling the mould cooled-down to 140-160°C, non-standard for the selected casting, and pouring temperature in the range of 705 to 720°C (higher than the recommended) of non-refined alloy. The castings were prepared with use of a high-pressure casting machine made by Kirov with mould closing force of 2500 kN. Occurrence of nonconformities was evaluated on properly prepared specimens taken from the castings manufactured with various parameters of the injection piston and various multiplication pressures. The results were subjected to quantitative and qualitative analyses of casting nonconformities and distribution of major alloying elements. It was found that proper selection of working parameters of the casting machine, in spite of disadvantageous pouring conditions, makes it possible to reduce occurrence of some casting defects, like shrinkage cavities and porosity, to improve tightness of castings even when the alloy refining process is omitted.

scholarly journals Lost Cores for High-Pressure Die Casting

2014 ◽  
Vol 14 (2) ◽  
pp. 101-104 ◽  
Author(s):  
P. Jelínek ◽  
E. Adámková
Keyword(s):  
High Pressure ◽  
Automobile Industry ◽  
Die Casting ◽  
Pressure Casting ◽  
Important Criterion ◽  
Solubility In Water ◽  
Grain Surface ◽  
Pressure Die Casting ◽  
The Given

Abstract Development of salt cores prepared by high-pressure squeezing and shooting with inorganic binders has shown a high potential of the given technology even for high-pressure casting of castings. Strength, surface quality of achieved castings, and solubility in water become a decisive criterion. The shape and quality of grain surface particularly of NaCl - cooking salts that can be well applied without anticaking additives has shown to be an important criterion. Thus the salt cores technology can cover increasingly growing demands for casting complexity especially for the automobile industry.

Microstructural evolution of an Al–Mg–Si–Mn– Fe alloy due to Ti and P addition

2021 ◽  
Vol 112 (9) ◽  
pp. 695-705
Author(s):  
Małgorzata Warmuzek ◽  
Adelajda Polkowska ◽  
Viktoria Boyko ◽  
Edward Czekaj ◽  
Konstantin Mikhalenkov ◽  
...  
Keyword(s):  
Mechanical Properties ◽  
High Pressure ◽  
Tensile Strength ◽  
Die Casting ◽  
The Other ◽  
Casting Technology ◽  
Microstructural Effects ◽  
Strength And Plasticity ◽  
Pressure Die Casting ◽  
P Addition

Abstract This paper presents the results of research on material and microstructural effects in a hypoutectic Al–Mg– Si–Mn–Fe alloy, modified by the addition of Ti and Ti + P, in two series of castings, gravity and pressure. It has been found that the use of high pressure die casting technology allows for significant improvement of mechanical properties, especially tensile strength and plasticity of the examined alloy. On the other hand, the addition of Ti and Ti + P caused different material effects. In gravity castings, the addition of Ti and Ti + P caused a decrease in strength and plasticity, while in high-pressure castings, an increase in the values of these parameters was observed. The microstructural effects related to the foundry technology and those caused by Ti and P additions were revealed, such as differences in the phase composition of the interdendritic eutectics and in the morphology and dispersion of their phase constituents: Mg2Si and α-Al(Fe,Mn)Si.

scholarly journals Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy

Metals ◽  
2021 ◽  
Vol 11 (11) ◽  
pp. 1747
Author(s):  
Eva Anglada ◽  
Fernando Boto ◽  
Maider García de Cortazar ◽  
Iñaki Garmendia
Keyword(s):  
Finite Element ◽  
High Pressure ◽  
Die Casting ◽  
Element Model ◽  
Finite Volume Methods ◽  
Gradient Boosting ◽  
Process Conditions ◽  
High Pressure Die Casting ◽  
Intrinsic Complexity ◽  
Pressure Die Casting

Simulation is a very useful tool in the design of the part and process conditions of high-pressure die casting (HPDC), due to the intrinsic complexity of this manufacturing process. Usually, physics-based models solved by finite element or finite volume methods are used, but their main drawback is the long calculation time. In order to apply optimization strategies in the design process or to implement online predictive systems, faster models are required. One solution is the use of surrogate models, also called metamodels or grey-box models. The novelty of the work presented here lies in the development of several metamodels for the HPDC process. These metamodels are based on a gradient boosting regressor technique and derived from a physics-based finite element model. The results show that the developed metamodels are able to predict with high accuracy the secondary dendrite arm spacing (SDAS) of the cast parts and, with good accuracy, the misrun risk and the shrinkage level. Results obtained in the predictions of microporosity and macroporosity, eutectic percentage, and grain density were less accurate. The metamodels were very fast (less than 1 s); therefore, they can be used for optimization activities or be integrated into online prediction systems for the HPDC industry. The case study corresponds to several parts of aluminum cast alloys, used in the automotive industry, manufactured by high-pressure die casting in a multicavity mold.

Three-Dimensional Microstructure Reconstruction and Finite Element Simulation of Gas Pores in the High-Pressure Die-Casting AZ91 Mg Alloy

2015 ◽  
Vol 21 (6) ◽  
pp. 1420-1425 ◽  
Author(s):  
Wei Jiang ◽  
Zhanyi Cao ◽  
Xu Sun ◽  
Haifeng Liu
Keyword(s):  
Mechanical Properties ◽  
Finite Element ◽  
High Pressure ◽  
Finite Element Simulation ◽  
Die Casting ◽  
Three Dimensional ◽  
Mg Alloy ◽  
High Pressure Die Casting ◽  
Element Simulation ◽  
Pressure Die Casting

AbstractHigh-pressure die-casting (HPDC) AZ91 tensile specimens were used to investigate characteristics of gas pores and their effects on mechanical properties of HPDC AZ91 magnesium (Mg) alloy. Combining the stereoscopic morphology of gas pores obtained from a three-dimensional (3D) reconstruction technique with the experimental data from uniaxial tensile testing, we worked on finite element simulation to find the relationship between gas pores and the mechanical properties of HPDC AZ91 Mg alloy. Results indicate that the 2D metallography images have one-sidedness. Moreover, gas pores >100 µm in the center region have a remarkable negative influence on the ultimate tensile strength (UTS) and elongation. With an increase in the size of large gas pores in the center region, the UTS and elongation of the material decreases. In addition, the distribution of gas pores in the specimens and the areal fraction of gas pores >100 µm on cross sections can also affect the UTS and elongation to some extent.

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