Analytical computation and experimental assessment of the effect of the plunger speed on tensile properties in high-pressure die casting

Fiorese, Elena; Richiedei, Dario; Bonollo, Franco

doi:10.1007/s00170-016-9758-y

Cited by 7 publications

(4 citation statements)

References 30 publications

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“…The optimal experimental conditions at steady-state, which guarantee a high quality of castings, were found to be: pouring temperature 690 °C, melt velocity at in-gates 51 m/s and filling time 9.7 ms. Indeed, the process parameters influence defect content and microstructure of castings, as it has been deeply studied in [ 13 ]. The cycle time was approximately 45 s.…”

Section: Results On the Expected Tensile Strength Of Al-si Alloys mentioning

confidence: 99%

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Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings—A Review

Anilchandra¹,

Arnberg

Bonollo

et al. 2017

Materials

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The tensile properties of an alloy can be exploited if detrimental defects and imperfections of the casting are minimized and the microstructural characteristics are optimized through several strategies that involve die design, process management and metal treatments. This paper presents an analysis and comparison of the salient characteristics of the reference dies proposed in the literature, both in the field of pressure and gravity die-casting. The specimens produced with these reference dies, called separately poured specimens, are effective tools for the evaluation and comparison of the tensile and physical behaviors of Al-Si casting alloys. Some of the findings of the present paper have been recently developed in the frame of the European StaCast project whose results are complemented here with some more recent outcomes and a comprehensive analysis and discussion.

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Section: Results On the Expected Tensile Strength Of Al-si Alloys mentioning

confidence: 99%

“…The reference casting #1 has been also adopted for the experimental validation of an analytical method for explaining and predicting the quality of castings, by means of the root means square plunger acceleration and the plunger speed extracted from the plunger displacement curve [ 12 , 13 ].…”

Section: Reference Castings For Testing Tensile Behaviormentioning

confidence: 99%

Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings—A Review

Anilchandra¹,

Arnberg

Bonollo

et al. 2017

Materials

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“…[18] Elena Fiorese et al conducted computational analysis and experimental assessment of effect of the plunger speed on tensile properties in high-pressure die casting using the software MAGMASOFT. [19] Antonio Armillotta et al performed the simulation of HPDCP of zinc alloys in order to reveal the occurrence of cold flow defects and found that the temperature at the end of the mold fill was important. [20] Abdel Illah Nabil Korti et al discovered that the air entrainment caused by the molten metal flow in the slow-stage of HPDCP in a horizontal cold chamber had an influence on the porosity defect of die casitings.…”

Section: Introductionmentioning

confidence: 99%

High-pressure die casting process optimization for improving shrinkage porosity and air entrainment in carburetor housing with aluminum alloy using Taguchi-based ProCAST simulation and MADM-based overall quality index

Kim,

Hong,

Yang

et al. 2024

Int J Adv Manuf Technol

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Many practical high pressure die casting process (HPDCP) optimization problems are multi-objective optimization ones that optimize multiple quality attributes of castings. This paper proposes a new HPDCP optimization method for improving shrinkage porosity and air entrainment using Taguchi-based ProCAST simulation and multi-attribute decision making (MADM)-based overall quality index. Taguchi orthogonal array is used to design ProCAST simulation experiment. MADM is used to convert multiple quality attributes into a single overall quality index (OQI). Taguchi optimization method is used to determine optimal HPDCP parameters to maximize the OQI. By using the proposed method, this paper determines the optimal HPDCP parameters such as pouring temperature (PT), filling rate (FR), piston velocity (PV) and preheating mold temperature (PMT) for improving volume of shrinkage porosity (VSP) and air entrainment (AE) in carburetor housing with aluminum alloy AlSi9Cu1Mg. The optimal HPDCP parameters are PT of 640 o C, FR of 40 %, PV of 6.5 m/s, and PMT of 150 o C. The PT is the most effective HPDCP parameter for improving the VSP and AE, and the next are FR, PV and PMT. The proposed method could be actively applied to not only HPDCP but also other casting processes and other manufacturing processes.

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“…The metamodeling approach has been used in many fields [5][6][7], but for the particular case of HPDC process, the number of works is reduced. The work of Fiorese et al in [8,9] was focused on the use of new predictive variables derived from plunger movement and the prediction of the ultimate strength of the cast parts. Krimpenis et al [10] used neural nets and predicted the misrun risks and the solidification time.…”

Section: Introductionmentioning

confidence: 99%

Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy

Anglada

Boto

Cortázar

et al. 2021

Metals

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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.

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Analytical computation and experimental assessment of the effect of the plunger speed on tensile properties in high-pressure die casting

Cited by 7 publications

References 30 publications

Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings—A Review

Evaluating the Tensile Properties of Aluminum Foundry Alloys through Reference Castings—A Review

High-pressure die casting process optimization for improving shrinkage porosity and air entrainment in carburetor housing with aluminum alloy using Taguchi-based ProCAST simulation and MADM-based overall quality index

Metamodels’ Development for High Pressure Die Casting of Aluminum Alloy

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