Study on Die Casting Simulation for Magnesium Alloy Cylinder Cover Based on JSCAST

2014 ◽  
Vol 800-801 ◽  
pp. 847-851
Author(s):  
Qing Ming Hu ◽  
Shi Gang Wang ◽  
Dong Sheng Li ◽  
Jian Hua Guo ◽  
Cheng Xu
Keyword(s):  
Magnesium Alloy ◽  
Production Efficiency ◽  
Simulation Analysis ◽  
Die Casting ◽  
Casting Process ◽  
Simulation Software ◽  
Casting Simulation ◽  
Filling Process ◽  
Automotive Engine ◽  
Die Casting Process

Magnesium alloy has widely been used in automotive sector due to its light weight, low density, high stiffness, and excellent casting performance and easy to recover and utilize. The magnesium alloy automotive engine cylinder cover was chosen as researching object to simulate its die casting filling process based on die casting filling process theory and numerical simulation analysis software JSCAST. The simulation results show that the utilization of die-casting simulation software for improving product quality and production efficiency has certain significance during the production of magnesium alloy die casting process.

Numerical Simulation of Die-Casting Magnesium Alloy Impeller with the Central Gating System

2011 ◽  
Vol 55-57 ◽  
pp. 2126-2129
Author(s):  
Xiao Chun Ma ◽  
Yi Qiang Zhuang ◽  
Ying Qi Tao
Keyword(s):  
Numerical Simulation ◽  
Temperature Field ◽  
Magnesium Alloy ◽  
Simulation Analysis ◽  
Die Casting ◽  
Casting Process ◽  
Gating System ◽  
Element Analysis ◽  
Pump Impeller ◽  
Die Casting Process

AZ91D magnesium alloy used as the automotive cooling system’s pump impeller material, using the finite element analysis software ProCAST to numerical simulation for the temperature field and the flow field of die-casting process, analyzed the defects causes of magnesium alloy die-casting, and then determined the gating system. Based on the results of numerical simulation analysis, the design of ingate of the gating system set on central department is reasonable. It's benefit for smooth filling of liquid metal and uniforming the temperature field distribution, so as to reduce casting porosity, cold shut and shrinkage defects.

Development of 2-Cavity Die Casting Process for AM50 Mg Steering Column Lock Housing Module

2006 ◽  
Vol 510-511 ◽  
pp. 334-337
Author(s):  
Shae K. Kim
Keyword(s):  
Magnesium Alloy ◽  
Aluminum Alloys ◽  
Magnesium Alloys ◽  
Weight Reduction ◽  
Die Casting ◽  
Casting Process ◽  
Research Strategy ◽  
Good Choice ◽  
Weight Basis ◽  
Die Casting Process

It is obvious that automotive industry worldwide is predicting significant growth in the use of magnesium alloys for weight reduction to decrease fuel consumption and emission. About a half decade ago, the price of magnesium alloys was more than twice that of aluminum alloys on a weight basis. Currently, magnesium alloys cost about one and a half times that of aluminum alloys on a weight basis, and thus the price of magnesium alloys is the same as or lower than that of aluminum alloys on a per volume basis. However, in considering the performance of magnesium components (not their specific mechanical properties) and recycling aspect of magnesium alloys, it is required to realize niche applications of magnesium alloys, which meet the cost requirement on performance basis and/or offer more than weight reduction. There are many other factors that make magnesium a good choice: component consolidation, improved safety for driver and passengers, and improved noise vibration and harshness (NVH), to name a few. As one of these efforts to adopt magnesium alloys in automotive component, this paper describes the research strategy of cold chamber type 2-cavity die casting of AM50 magnesium alloy for developing the steering column lock housing module with emphasis on cost driving factors and necessities for cost reduction, explaining why AM50 magnesium alloy is chosen with design and die casting process optimization.

Numerical Simulation on the Filling Process of Rheological Die Casting and Forming Defects Analysis

2012 ◽  
Vol 192-193 ◽  
pp. 293-298 ◽  
Author(s):  
Fan Zhang ◽  
Nan Nan Song ◽  
Jun Zhang ◽  
Yong Lin Kang ◽  
Qiang Zhu
Keyword(s):  
Numerical Simulation ◽  
Die Casting ◽  
A356 Alloy ◽  
Casting Process ◽  
Solid Particles ◽  
Filling Process ◽  
Die Casting Process ◽  
Defects Analysis ◽  
Semi Solid ◽  
Forming Defects

According to semi-solid slurry rheological behavior, an apparent viscosity model of A356 alloy developed based on the Carreau model was established to simulate filling process of rheo-diecasting about automobile shock absorber parts and to compare with conventional liquid filling process. Numerical simulation results showed that the filling process of rheo-diecasting was smooth but difficult to splash, which reduced the tendency of the alloy oxidation and inclusion. Meanwhile, a certain percentage of the primary solid particles precipitated before filling and solidification shrinkage of semi-solid slurry were small. This benefited to reduce or eliminate shrinkage defects of the castings. Compared with conventional liquid die casting process, rheo-diecasting process had unique advantages in reducing the internal defects and improving mechanical properties of castings.

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.

Study on Pressure Variations in the Mold of Magnesium Alloy Die Castings

2007 ◽  
Vol 353-358 ◽  
pp. 1614-1616
Author(s):  
Yan Gai Liu ◽  
Zhao Hui Huang ◽  
Hao Ding ◽  
Ming Hao Fang ◽  
Shou Mei Xiong
Keyword(s):  
Magnesium Alloy ◽  
Real Time ◽  
Time Pressure ◽  
Die Casting ◽  
Solidification Process ◽  
Casting Process ◽  
Mold Filling ◽  
Die Casting Process ◽  
Die Castings ◽  
Filling And Solidification

High pressure die casting is the most common method in making magnesium alloys for both auto parts and 3C products. Pressure variations in the mold during mold filling and solidification process have direct influences on the quality and properties of die castings. In this paper, a cylinder head cover was produced to experimentally study pressure variations in the mold during magnesium alloy die-casting process in real time for the first time. Pressure varies at different positions in the mold during die casting process. This study indicates that mold filling and solidification process of magnesium alloy die castings can be described by pressure curves obtained by pressure measurement at different test positions in the cavity in real time.

Numerical Simulation of Gas-Liquid Tow-Phase Flow During Complex Mold Filling Process

2012 ◽  
Vol 591-593 ◽  
pp. 631-634
Author(s):  
Jun Ming Feng ◽  
Fan Jiang
Keyword(s):  
Numerical Simulation ◽  
Molten Aluminum ◽  
Simulation Analysis ◽  
Die Casting ◽  
Great Influence ◽  
Casting Process ◽  
Filling Process ◽  
Analysis Technique ◽  
Molten Aluminum Alloy ◽  
Complex Casting

In order to predict defects of a complex casting that may arise during the die casting, The numerical analysis technique of Fluent' s VOF was used to establish the filling model. Based on the case of the wheel, it is expounded that the numerical simulation of VOF was utilized in application of casting. The five groups of simulation analysis were performed under the different pouring pressure. At last the pouring pressure has a great influence on the state of filling and the filling times are little difference. The research on pouring pressure and flow field during the casting process of wheels was conducted. The results of the study show that, when the pouring pressure is about 60000 KPa, the cavity is completely filled with the molten aluminum alloy.

Sign in / Sign up

Export Citation Format

Share Document