Finite element analysis for die casting parameters in high-pressure die casting process

Abstract

The gating system and the overflow system were designed according to the casting structure during high pressure die casting (HPDC) process. The simulation was carried out by ProCAST software to visualize the injection chamber pre-crystallization and the flow of molten metal. The main work is to research four die casting process parameters, i.e. injection temperature, low-pressure velocity, high-and low-pressure velocity's switching position, and high-pressure velocity. Experimental results show that the higher injection temperature and lowpressure velocity can mitigate the pre-crystallization of the injection chamber. However, when the low-pressure velocity exceeds 0.2 m·s -1 , the air entrapment in the chamber occurs. Besides, when the high-pressure velocity is greater than 2.5 m·s -1 , the overflow channel at the final filling position is covered by the liquid metal too early. Finally, the injection temperature of 650 °C, the low-pressure velocity of 0.2 m·s -1 , the high-and low-pressure velocity's switching position of 320 mm and the high-pressure velocity of 2 m·s -1 are obtained as the optimal parameters by the software simulation, which has been verified by actual production.

Research and Evaluation of the Influence of the Construction of the Gate and the Influence of the Piston Velocity on the Distribution of Gases into the Volume of the Casting

“…As the mean thickness of the cast h reaches the value of 2 mm for the particular cast and maximal cast length l (in this case it is the cast diameter) reaches the value of 116.5 mm, the melt velocity in the gate for reference gating system is determined to the value of v G1 = 35 m·s −1 . By means of continuity Equation (1) and taking into consideration the closed system [ 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 22 , 23 , 24 , 25 , 26 , 27 , 28 ], piston velocity is determined v P1 = 2.8 m·s −1 : S G × v G = S P × v P , …”

“…Right in the gate final acceleration of the melt flow occurs as well as its forming before entering the mold shaping cavity. Velocity in the gate determines the filling mode of the mold shaping cavity on the basis of which it is possible to predict development of the gas entrapment in the cast volume [ 24 , 25 , 26 , 27 , 28 ].…”

“…The objective pursued is to achieve reduction of distribution of gases to the cast volume during die casting cycle. On the basis of knowledge and information published in [ 10 , 11 , 12 , 13 , 14 , 15 , 16 , 17 , 22 , 23 , 24 , 25 , 26 , 27 , 28 ] it is possible to understand the system of filling chamber—shaping cavity—as a closed system (pipeline). On the basis of hydrodynamics it can be thus assumed that velocity in the gate with preservation of constant flow rate of the melt is influenced by the cross section of the gate or by velocity of the piston.…”

Numerical Simulation of Latent Heat of Solidification for Low Pressure Casting of Aluminum Alloy Wheels

“…This study uses ProCAST [14] low-pressure casting simulation software to simulate the solidification process of aluminum alloy wheels. ProCAST software is a simulation software for the casting process developed by the United States UES (UNIVERSAL ENERGY SYSTEM) company (Fairfield, CT, USA).…”

The Stress Concentration Mechanism of Pores Affecting the Tensile Properties in Vacuum Die Casting Metals

“…The research showed that vacuum-assisted casting strongly reduced the porosity of die castings and increased their density and mechanical properties of tensile strength and elongation. The numerical simulation of vacuum die casting can be used to improve the prediction accuracy of the defect position and elongation of die castings; in these studies, data have been obtained by simulation tests and verified by experiments [22][23][24][25][26].…”