Numerical Simulations of Low Pressure Die-Casting for A356 Aluminum Rims

Abstract

This study conducted mold flow analyses on low pressure die-casting A356 aluminum rims to improve the shrinkage and porosity defects which usually occurs in die-castings so as to enhance the quality of die-casting wheels. We adopted different lift tube designs with cylindrical, taper opening and back taper opening structures while discussing the filling, exhaust, and solidification of molten flows and predicting the shrinkage and porosity formed based on the retained melt modulus. The study found that the configuration of lift tube as well as the optimization of process parameters such as the processing pressure and progressive time could effectively reduce the formations of shrinkage and porosity defects and improve the quality of die-castings.

Preventing Casting Defects of Stainless Steel Flanges Using a Water-Soaking Method

“…Their research eliminated shrinkage and porous defects, which are common in investment casting. Huang et al [12] examined various stalk tube configurations and then used RMM simulation to optimize die casting pressure and time parameters for predicting shrinkage and pinhole defects in die casting. Song et al [13] adopted CAE to simulate the solidification process of valve casting with various numbers of risers and potential defects, such as poured short, cold shut, air entrapment, and slag inclusion during the casting process.…”

Numerical simulation and design of casting system for stainless steel exhaust manifold

“…Casting products must undergo strict quality inspections to meet relevant specifications. Improving various casting defects is the goal of the casting industry, and to enhance casting quality and yield while reducing labor costs, many researchers have developed molten metal flow analysis methods for casting defect prediction using computer-aided engineering (CAE) [1][2][3][4][5][6][7][8][9][10]. At present, the majority of casting manufacturers in Taiwan use trial and error to derive optimal casting schemes.…”