Simulations of Die Casting With Uncertainty Quantification

Abstract

Die casting is a type of metal casting in which a liquid metal is solidified in a reusable die. In such a complex process, measuring and controlling the process parameters are difficult. Conventional deterministic simulations are insufficient to completely estimate the effect of stochastic variation in the process parameters on product quality. In this research, a framework to simulate the effect of stochastic variation together with verification, validation, and uncertainty quantification (UQ) is proposed. This framework includes high-speed numerical simulations of solidification, microstructure, and mechanical properties prediction models along with experimental inputs for calibration and validation. Both experimental data and stochastic variation in process parameters with numerical modeling are employed, thus enhancing the utility of traditional numerical simulations used in die casting to have a better prediction of product quality. Although the framework is being developed and applied to die casting, it can be generalized to any manufacturing process or other engineering problems as well.

Optimization of solidification in die casting using numerical simulations and machine learning

“…The single objective response surfaces were used to get an insight regarding the conflicting nature of the objectives since the individual optimal solutions were completely different from each other. Moreover, the solidification time, maximum grain size and minimum yield strength varied in the ranges [2, 3.5] seconds, [22,34] microns and [134, 145] MPa respectively for the given inputs.…”

“…In our work, we have first generated a tetrahedral mesh using GMSH [20] and then divided into a hexahedral mesh using TETHEX [21]. The details of the numerical algorithm and verification and validation of OpenCast are discussed in previous publications [15,22]. A model geometry representing a clamp [15] has been considered to illustrate the methodology.…”

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“…In this experimental work, the specimen component was extracted from pressure die casting for analyzing various properties. 35,36…”

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