Simulation Study on HPDC Process for Automobile Part with Aluminum Alloy

Abstract

In this research, in order to optimize casting design of an automobile part (Gear Box), Computer Aided Engineering (CAE) was performed by using the simulation software (Z-Cast). The simulation results were analyzed and compared with experimental results. During the filling process, internal porosities caused by air entrap were predicted and reduced remarkably by the modification of the gate system and the configuration of overflow. With the solidification analysis, internal porosities caused by the solidification shrinkage were predicted and reduced by the modification of the gate system. For making better permanent High Pressure Die Casting (HPDC) mold, cooling systems on several thick areas are proposed in order to reduce internal porosities caused by the solidification shrinkage.

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

“…The calculated area of the inner gate is ~430 mm 2 . the calculated cross-sectional area of the runner is 1,290 mm 2 , and the ratio of it to cross-sectional area of the gate is 1:3 [6][7][8][9] . A branch was drawn on the right side of the runner to collect the cold metal liquid and to improve the quality of the casting.…”

“…Considering the wider channel can lead to the lower resistance to the flow of liquid metal [5] , the inner gate position is set at the place of the thicker wall, circled by the yellow outline. In addition, the inner gate was designed with edge- Research & Development lapping [6] . The cross-sectional area of the gate could be calculated by Eq.…”

“…where, A g is the cross-sectional area of the inner gate (mm 2 ); V is the sum of the volume of die casting and overflow groove, which is 650,000 mm 3 ; v is the filling velocity of the molten metal at the gate, which is 25,000 mm·s -1 ; t is the filling time which is 0.06 s [6][7][8][9] . The calculated area of the inner gate is ~430 mm 2 .…”

“…The locations circled by the red lines in Fig. 1(b) are the thicker edge and the last filling position, and some overflow slots were added for these locations [6] . To increase the connection effect of the four walls of the casting, an overflow tank was added at the top to enhance gas circulation [7][8][9] .…”