Abstract:The die casting industry is under increasing pressure to improve production rates to enable greater productivity. The potential to decrease the cycle time is of great significance. A small reduction in the cycle time can significantly improve production rates.Employing conformal cooling channels allows improvements to be made to die performance through the reduction of solidification times. The paper reviews simulated solidification results from a traditional cooling channel design and a conformal cooling channel design. The paper continues by describing the construction of bonded laminate insert with integrated cooling channels. Casting trials were conducted using the inserts to validate the simulated results. Work to date has demonstrated the ability to manufacture laminate inserts quickly, the accuracy of computational fluid dynamics and the importance of conformal cooling design.

This paper details the development of a rapid tooling manufacturing route for the gravity and high-pressure die-casting industries, resulting from an EPSRC funded collaborative research project between the Universities of Warwick, Loughborough and DeMontfort, with industrial support from, amongst others, MG Rover, TRW Automotive, Sulzer Metco UK Ltd and Kemlows Diecasting Products Ltd. The developed process offers the rapid generation of mould tools from laser-cut laminated sheets of H13 steel, bolted or brazed together and finish machined. The paper discusses the down-selection of materials, bonding methods and machining methods, the effect of conformal cooling channels on process efficiency, and the evaluation of a number of test tools developed for the industrial partners. The paper also demonstrates the cost and time advantages (up to 50 and 54 per cent, respectively) of the tooling route compared to traditional fabrication methods.

The objective of this work was to determine the temperature experienced within a pressure die-casting tool during aluminium part production. It was important to determine the temperature profile of the production process so that an accurate thermal cycle could later be simulated. The research overcame several challenges of this aggressive environment to show that the surface temperature of a die could be obtained from an H13 steel tool running on an aluminium pressure die-casting machine. The results show that the surface of a typical aluminium pressure die-casting tool heats to 400–450°C within approximately 1 s and cools to 150–200°C within approximately 20 s.

The manuscript was received on 20 November 2006 and was accepted after revision for publication on 6 March 2007. DOI: 10.1243/09544054JEM787Abstract: The objective of this research was to investigate a new test procedure for simulating the temperatures in die casting so that materials can be evaluated as tool materials for the high-pressure die casting of aluminium. Other procedures have been used for evaluating the thermal fatigue performance of tool materials, but these tests do not reproduce all the conditions found in production environments. A new test method has been established that enables the thermal fatigue resistance of materials to be identified. The test is robust, reliable, and versatile and has a large operating temperature range (25-1200˚C), and the cycle times and dwell times are adjustable. The results have shown a similar number of cycles to induce the same level of fatigue cracking as in actual die-casting tools. The performance of different materials can be compared, and an approximate fatigue life for high-pressure die-casting tools can be determined.