Determination of the metal/die interfacial heat transfer coefficient of high pressure die cast B390 alloy

Cao, Yongyou; Zhang, Guo; Xiong, Shengwu

doi:10.1088/1757-899x/33/1/012010

Cited by 14 publications

(10 citation statements)

References 5 publications

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“…Since no precise information can be given at this point, the value was set to 10,000 W/(m 2 K). In contrast to this, numerous research groups have investigated the heat transfer coefficient during solidification of the casting [20][21][22][23][24][25][26] and during the spraying process. [27][28][29] An evaluation of the available literature revealed that both heat transfer processes are strongly influenced by the surface temperature, geometry and process parameters.…”

Section: Thermal Propertiesmentioning

confidence: 99%

“…The metal/die interfacial heat transfer coefficient was assumed to be a constant value of 20,000 W/(m 2 K), thus taking into account an order that can be found in numerous publications. 21,26 The heat transfer coefficient during spraying was set to a uniform value of 15,000 W/(m 2 K) for the cavity area and directly adjacent areas. Surface areas that are not directly in the spray cone of the die spraying system were set to a heat transfer coefficient of 3000 W/(m 2 K).…”

Section: Thermal Propertiesmentioning

confidence: 99%

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An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach

Müller

Rothe

et al. 2018

Inter Metalcast

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High-pressure die casting dies are produced in most cases by conventional subtractive manufacturing processes. In this case, a massive design of the die usually ensures high stability during the casting process. However, at the same time, it leads to low flexibility in casting production and high material costs. The basic approach in the present work is to reduce the conventional subtractive production process of a die casting die in favor of a flexible, modular design, where only a few contour elements of the die have to be replaced for achieving different castings. In order to pave the way for this design principle, basic thermal and structural properties of a lightweight design die casting die were analyzed. The finite element calculations carried out showed that the modular lightweight die casting die consumes considerably less energy for preheating and during operation. Due to the reduced stiffness and material, however, calculated deformations and stresses in the die are considerably higher during the casting process. Although the initial calculation results look very promising, further knowledge must be gained in order to ensure the future success of modular lightweight die casting dies.

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Section: Thermal Propertiesmentioning

confidence: 99%

Section: Thermal Propertiesmentioning

confidence: 99%

An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach

Müller

Rothe

et al. 2018

Inter Metalcast

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“…The utilization of these, whose materials are mainly aluminum and magnesium alloys, in the automotive industry has therefore significantly increased in the past few years [1] . However, the mechanical properties of these components are often deteriorated by defects such as shrinkage and gas pores due to inappropriate casting technologies [2][3][4] .Thus, it is very important to find an appropriate casting technology. Squeeze casting (SC) is a promising near net-shape processing technique, where the molten metal solidifies under a relatively high external pressure, and the fabricated components are normally free of shrinkage and gas pores [5] .…”

mentioning

confidence: 99%

mentioning

confidence: 99%

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

Wang

et al. 2017

China Foundry

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Male, born in 1968, Ph.D., Associate Professor. His research interests mainly focus on high integrity and near net shape casting technology for lightweight metal alloys, aluminum and magnesium alloys squeeze casting process and its macro and microscopic modeling, multi-scale and multi-discipline modeling and computation of solidification and casting processes. L ightweight components have vital importance due to weight reduction in vehicles because of high strength-to-weight ratio. The utilization of these, whose materials are mainly aluminum and magnesium alloys, in the automotive industry has therefore significantly increased in the past few years [1] . However, the mechanical properties of these components are often deteriorated by defects such as shrinkage and gas pores due to inappropriate casting technologies [2][3][4] .Thus, it is very important to find an appropriate casting technology. Squeeze casting (SC) is a promising near net-shape processing technique, where the molten metal solidifies under a relatively high external pressure, and the fabricated components are normally free of shrinkage and gas pores [5] . In the squeeze casting process, process parameters Abstract: As an advanced near-net shape technology, squeeze casting is an excellent method for producing high integrity castings. Numerical simulation is a very effective method to optimize squeeze casting process, and the interfacial heat transfer coefficient (IHTC) is an important boundary condition in numerical simulation. Therefore, the study of the IHTC is of great significance. In the present study, experiments were conducted and a "plate shape" aluminum alloy casting was cast in H13 steel die. In order to obtain accurate temperature readings inside the die, a special temperature sensor units (TSU) was designed. Six 1 mm wide and 1 mm deep grooves were machined in the sensor unit for the placement of the thermocouples whose tips were welded to the end wall. Each groove was machined to terminate at a particular distance (1, 3, and 6 mm) from the front end of the sensor unit. Based on the temperature measurements inside the die, the interfacial heat transfer coefficient (IHTC) at the metal-die interface was determined by applying an inverse approach. The acquired data were processed by a low pass filtering method based on Fast Fourier Transform (FFT). The feature of the IHTC at the metal-die interface was discussed.

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“…Hence, the research of tools for controlling the process and optimizing its parameters is widely recognized as a challenge for the HPDC industry [5]. Several works in the literature attempt to investigate this relevant issue, by studying the effect on the final outcome of different types of process parameters, such as kinematic parameters of the plunger (speed or position) [6][7][8], pressure parameters (e.g., intensification pressure) [8] and thermal characteristics of the melt and the die cavity (e.g., pouring temperature, thermoregulation and lubrication systems of the die) [9][10][11]. Particular attention has been paid to the first type of process parameters, i.e.…”

mentioning

confidence: 99%

Improving the quality of die castings through optimal plunger motion planning: analytical computation and experimental validation

Fiorese

Richiedei

Bonollo

2016

Int J Adv Manuf Technol

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High-pressure die casting is a process widely used to manufacture components with high productivity and dimensional accuracy. Its main disadvantage is the high percentage of scraps, due to a high amount of defects. Thus, the identification of the parameters affecting quality of castings is the current challenge towards an efficient and effective production. In their previous work, the authors have found and statistically validated a novel parameter explaining and forecasting both static mechanical properties and porosity of castings. Such a parameter, defined as the root mean square value of the plunger acceleration in the fast shot stage, represents a measure of the average force transmitted by the plunger to the melt and has been proved to be very effective in predicting casting quality. In order to provide a practical tool for the use of this parameter, this work proposes an analytical method for its computation, starting from the plunger displacement curve or just some notable points. The method formulation takes advantage of the analytical development of the typical motion primitives adopted and also accounts for limitations due to the machine. Hence, the optimization of the process can be achieved by selecting in advance the most suitable plunger motion profile, among those feasible, that allows to improve the casting quality. Besides the theoretical formulation, a meaningful experimental validation is provided to demonstrate the correctness of the proposed parameter and of the analytical approach, as well as its ease of implementation that makes it suitable for industrial applications.

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Determination of the metal/die interfacial heat transfer coefficient of high pressure die cast B390 alloy

Cited by 14 publications

References 5 publications

An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach

An Initial Study of a Lightweight Die Casting Die Using a Modular Design Approach

Measurement of temperature inside die and estimation of interfacial heat transfer coefficient in squeeze casting

Improving the quality of die castings through optimal plunger motion planning: analytical computation and experimental validation

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