Design and optimization of gating system, modification of cooling system position and flow simulation for cold chamber high pressure die casting machine

Jadhav, Amol R.; Hujare, Deepak; Hujare, Pravin P.

doi:10.1016/j.matpr.2020.11.346

Cited by 4 publications

(3 citation statements)

References 9 publications

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“…Since the mold design has a significant impact on the quality of casting processes, process simulation is often used to optimize the ingate system or mold design to optimize, respectively, the process or the quality of the casted part. For example, [27] uses process simulation to optimize the effect of cooling system location on the stresses produced in the mold, to enhance the mold life. Additionally, [28] uses CFD simulations to analyze the filling of the cavity and quantifies porosities.…”

Section: Combining Structural Optimization and Process Assurancementioning

confidence: 99%

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

et al. 2021

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The structural optimization of manufacturable casting parts is still a challenging and time-consuming task. Today, topology optimization is followed by a manual reconstruction of the design proposal and a process assurance simulation to endorse the design proposal. Consequently, this process is iteratively repeated until it reaches a satisfying compromise. This article shows a method to combine structural optimization and process assurance results to generate automatically structure- and process-optimized die casting parts using implicit geometry modeling. Therefore, evaluation criteria are developed to evaluate the current design proposal and qualitatively measure the improvement of manufacturability between two iterations. For testing the proposed method, we use a cantilever beam as an example of proof. The combined iterative method is compared to manual designed parts and a direct optimization approach and evaluated for mechanical performance and manufacturability. The combination of topology optimization (TO) and process assurance (PA) results is automated and shows a significant enhancement to the manual reconstruction of the design proposals. Further, the improvement of manufacturability is better or equivalent to previous work in the field while using less computational effort, which emphasizes the need for suitable metamodels to significantly reduce the effort for process assurance and enable much shorter iteration times.

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Section: Combining Structural Optimization and Process Assurancementioning

confidence: 99%

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

et al. 2021

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“…Suresha and Pawan used Z-cast to design the mold and gate system for a heat sink [1]. Ramnath et al performed analytic calculations in highpressure casting for the design of the runner and confirmed the results by casting simulation [5]. Sulaiman and Keen performed flow analysis along the runner and gating system of a casting process using four gates and the angles of the branches leading to the gate [6].…”

Section: Introductionmentioning

confidence: 99%

Design and optimization of runner and gating systems, in high-pressure casting and sand casting, for an aluminum alloy valve cover

KUYUMCU,

HAKTANIR

2023

International Journal of Automotive Engineering and Technologies

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The weight and speed advantage of aluminum die-casting leads to its use in many parts in the automotive industry. Casting simulation programs are used, to avoid time-consuming and expensive production costs, and to design the production process. For casting production one of the most important factors is the runner design, which directly affects castability, material selection, and casting quality. With the correct design of runner systems, there will be no problem with the casting part. In this study, the final part and the runner design for the aluminum alloy valve cover were modeled in CAD, according to the empirical calculations. Furthermore, an appropriate casting method was selected for the valve cover not only according to the results of both high-pressure die-casting and sand-casting simulations but also economic calculations. The main technical parameters for selection were mold and part temperature distribution, liquid metal flow rates, cold shut possibilities, final air quantities, microporosity, and microporosity values. After the final decision, the casting part was produced with high pressure die casting by the implementation of the final runner design.

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“…In the work of Hu et al [ 28 ], experimental and numerical data were employed to predict different designs of the runner and the gating system. In further studies, CFD (Computational Fluid Dynamics) was also used to analyse the influence of acceleration parameters and the filling fraction on air entrapment in the shot sleeve [ 29 , 30 ] to evaluate the critical velocity in the shot sleeve [ 31 ], to carry out the thermal analysis of the pressure die-casting process [ 32 , 33 , 34 ], or to evaluate the overall process performance with CAE (Computer Aided Engineering) [ 35 , 36 ].…”

Section: Introductionmentioning

confidence: 99%

A Decision Support System (DSS) for the Prediction and Selection of Optimum Operational Parameters in Pressure Die-Casting Processes

2022

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A large number of material and process parameters affect both the part quality and the process performance in pressure die-casting (PDC) processes. The complex relations between most of these variables make PDC process optimisation a difficult issue which has been widely studied for many years. Although there are several analytical and numerical models to optimise certain process parameters, it is difficult to establish a specific operational configuration for PDC machines that ensures the joint optimisation of these variables. Therefore, in this study, some of these optimisation models have been implemented in a Decision Support System (DSS) that allows us to define an operational region that establishes a setup of machine parameters that ensures the manufacture of quality parts. By using this DSS, the user can set the values of the input variables related to the casting material, the die, or the casting machine. Then the corresponding calculations are made by the system and the results are expressed in terms of certain output variables such as the maximum filling time, maximum filling fraction, or the plunger velocity profile among others. The DSS allows the user to estimate the influence between input and output variables and find proper values for the input variables to achieve an optimum operational range. Consequently, improved process performance can be achieved taking into account productivity, part quality, and economic aspects.

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Design and optimization of gating system, modification of cooling system position and flow simulation for cold chamber high pressure die casting machine

Cited by 4 publications

References 9 publications

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

Combining Structural Optimization and Process Assurance in Implicit Modelling for Casting Parts

Design and optimization of runner and gating systems, in high-pressure casting and sand casting, for an aluminum alloy valve cover

A Decision Support System (DSS) for the Prediction and Selection of Optimum Operational Parameters in Pressure Die-Casting Processes

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