Improving the design of nozzles used in zamak high-pressure die-casting process

Sousa, Vítor F. C.; Silva, F.J.G.; Ferreira, Luı́s Pinto; Campilho, R.D.S.G.; Pereira, Teresa; Braga, Erika

doi:10.5937/fme2104005s

Cited by 6 publications

(3 citation statements)

References 37 publications

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“…This makes production via HPDC economical [1,2]. The process is extremely fast and since die casting is precise and repeatable, the castings are almost in their final state, requiring relatively small or no finishing operations [3]. The mould is one of the most important parts of the HPDC process.…”

Section: Introductionmentioning

confidence: 99%

Introduction to the Methodology of the Study of Operational Wear of Experimental Shaped Parts of Moulds for HPDC of Zinc Alloys

KOZA,

GRYC,

SOCHA

et al. 2023

METAL Conference Proeedings

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This research article introduces a methodology for studying the operational wear of experimental shaped parts of moulds for high-pressure die casting (HPDC) of zinc alloys. The study includes roughness analysis and geometric dimensioning and tolerancing (GD&T) based on a coordinate measuring machine (CMM) and 3D scanning to quantify the wear of the mould parts due to contact with the zinc alloy melt and solidifying castings during the HPDC process cycles. The research aims to improve the understanding of the mechanisms of mould wear in HPDC of zinc alloys if different types of steel grades and their production technologies are applied during a hundred thousand casting cycles. The results show roughness and geometrical changes on the surface of shaped parts of moulds made from H11 steel grade conventionally, respectively additively manufactured by selective laser melting (SLM).The results so far have shown that the shaped parts of the mould made of conventional H11 steel after 500,000 or additively manufactured H11 steels show the good shape and surface stability after 100,000 casting cycles. Until now, it has not been possible to determine the negative effect of the given HPDC process on the wear of the studied shape parts of the moulds using the above methods; the analyses will continue until their final wear. In parallel with evaluating the shape and surface of the shaped parts, these parameters are also assessed for the zinc alloy castings. However, the evaluation can't be squeezed into the required scope of this contribution. In the following research phase, also metallographic methods will be applied to study the quality parameters of both shaped mould inserts (after their wear) and castings (after different numbers of casting cycles) too. The final and tested methodology, in connection with other extensive outputs of the research and development carried out within the framework of the solved project, should be helpful for designers and manufacturers of shaped parts of moulds and for the own HPDC of zinc alloys.

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Section: Introductionmentioning

confidence: 99%

Introduction to the Methodology of the Study of Operational Wear of Experimental Shaped Parts of Moulds for HPDC of Zinc Alloys

KOZA,

GRYC,

SOCHA

et al. 2023

METAL Conference Proeedings

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“…Aluminum and zinc alloys are commonly employed in the automotive industry, with Zamak being quite used. As such, there have been some recent studies about the improvement of the casting [9,10] and injection of these alloys [11]. These alloys are particularly used in the production of components such as Bowden cables.…”

Section: Introductionmentioning

confidence: 99%

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

et al. 2022

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The automotive industry is one of the driving forces of the global industry; thus, it is a very competitive sector which creates a constant need for process improvement, regarding productivity, quality, and flexibility. Automation has proven to be a viable solution for these production problems, with the rising adoption of these automated system by companies that try to design and implement more flexible systems, while reducing costs and improving process quality. Furthermore, the use of automation reduces the manpower factor and its associated variability. In the present work, a new concept for a Bowden cable production process is presented by employing the design science research (DSR) methodology. The project starts with the analysis of the previous production concept, determining possible problems and improvements, as well as setting objectives/requirements for a possible new concept/equipment. This information was used to develop a new automated Bowden cable production equipment, implementing several changes to the old concept and filling a gap in the literature in this field. The developed system was implemented and tested. A considerable reduction in cycle time was registered by 25%, which resulted in an increase of 30% in process productivity.

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“…This is the commonly used process to produce the tip blockers of Bowden cables, parts handled on a daily basis, when we open the car door, the hood, the trunk door, the handbrake or when we go up and down a window in a car window [24]. The injection nozzle area and corresponding connection to the mold have under-gone some changes in recent years, but not enough to avoid constant replacements, process stoppages and productivity losses [25]. Thus, it became urgent to invest in research in a new concept of nozzle and con-necting zone, in order to increase the efficiency of the process, acting essentially in the previously mentioned areas.…”

Section: Introductionmentioning

confidence: 99%

Case-based product development of a high-pressure die casting injection subset using design science research

Tojal¹,

Silva²,

Campilho³

et al. 2022

FME Transactions

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High pressure die casting is widely used in metalworking industry. Many of the components and devices directly linked to the hot parts are subjected to severe wear. However, some design updates can enlarge the lifespan of these components and devices. This paper proposes to show how a sustainable maintenance can be obtained by focusing resources on the analysis of the critical problem and its consequent mitigation, whereas they are originated on the human, machine/process or supplier level. Design science research (DSR) was the iterative research methodology chosen to integrate this work. The completion of the objective with the implementation of this new injection subset concept brought extremely beneficial results, such as reduction of its consumption, reduction of acquisition cost and waste generated, and reduction of the intervention time during maintenance operations, as well as increase in equipment availability time.

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Improving the design of nozzles used in zamak high-pressure die-casting process

Cited by 6 publications

References 37 publications

Introduction to the Methodology of the Study of Operational Wear of Experimental Shaped Parts of Moulds for HPDC of Zinc Alloys

Introduction to the Methodology of the Study of Operational Wear of Experimental Shaped Parts of Moulds for HPDC of Zinc Alloys

Developing a Novel Fully Automated Concept to Produce Bowden Cables for the Automotive Industry

Case-based product development of a high-pressure die casting injection subset using design science research

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